Technical Articles - Hydraulics Plant Maintenance Resource Center

Technical Articles - Hydraulics

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Articles on Maintenance of Hydraulic Systems

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Carrying Out Effective Repairs To Hydraulic Cylinders The following is a guide to carrying out effective repairs to hydraulic cylinders Cylinder mounting dangers in fluid power Pay attention to the load-carrying capabilities of fluid power cylinder mountings to prevent their misapplication, or you could end up with premature cylinder failure, serious machinery problems or safety issues Defining And Maintaining Fluid Cleanliness For Maximum Hydraulic Component Life This article, an extract from the first chapter of Brendan Casey's excellent book "Insider Secrets to Hydraulics" gives some highly practical tips for extending the life of, and increasing the reliability of, your hydraulic systems. - requires free Adobe Acrobat Reader for viewing.

http://www.plant-maintenance.com/maintenance_articles_hydraulics.shtml (1 of 2) [5/12/2004 11:28:09 PM] Technical Articles - Hydraulics

Developing PMs for Hydraulic Systems We often accept hydraulic system failure as normal and use resources preparing for failure rather than deciding not to accept hydraulic failure as the norm and strive to eliminate it. In 1980, Kendall Co. changed their focus from reactive to proactive maintenance and practically eliminated unscheduled hydraulic failure - requires free Adobe Acrobat Reader for viewing. Preventing hydraulic and pneumatic cylinder failures Proper sizing of piston rods and prudent selection of stop tubes, especially in long-stroke cylinders, can save a lot of downtime and expense Understanding fluid power diagrams How to read hydraulic and pneumatic circuit drawings. When should you use fluid power motors? Making the right motor choice for automation applications involves several decisions based on operating conditions and environment.

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http://www.plant-maintenance.com/links.shtml [5/12/2004 11:29:48 PM] Carrying Out Effective Repairs To Hydraulic Cylinders

For more products related to this Carrying Out Effective Repairs To Hydraulic Cylinders topic visit our Product Showcase By Brendan Casey

As a product group, cylinders are almost as common as pumps and motors For other articles combined. They are less complicated than other types of hydraulic related to this topic components and are therefore relatively easy to repair. As a result, many visit our Reference hydraulic equipment owners or their maintenance personnel carry out Library. cylinder repairs themselves.

The following is a guide to carrying out effective repairs to hydraulic cylinders. The extent of the repair work that can be carried out in-house depends on the extent of wear or damage to the cylinder and how well top equipped your repair shop is. As with any repair, the economics of proceeding with a repair on a cylinder are ultimately dependent on the cost and availability of a new one. Need more training? Disassembly And Inspection Search Database of training courses and Typically, a cylinder will have been removed for repair due to either conferences on these external or internal leakage. Close inspection of the parts of the cylinder subjects in our after disassembly, particularly the seals, can reveal problems that may not Tradeshow/Seminar otherwise be obvious. Search Section

Piston seal - If the piston seal is badly distorted, eroded or missing completely, this indicates that the barrel is oversize or has bulged in service. In this case, the barrel or the complete cylinder should be replaced. Replacing the piston seal without replacing the barrel is a short- term fix only.

Rod seal - If the rod seal is badly distorted, this usually indicates that either the guide bush is excessively worn or the rod is bent. In both cases this results in the weight of the rod riding on the seal, which causes it to fail. Replacing the rod seal without identifying and rectifying the cause of the problem is a short-term fix only.

Rod - Check the rod for cracks at all points where its cross-section changes. Dye penetrant is ideal for this purpose. It is easy to use and readily available from industrial hardware merchants.

Inspect the chrome surface of the rod. If the chrome looks dull on one side and polished on the opposite side, this indicates that the rod is bent. Rod

http://www.maintenanceresources.com/ReferenceLibrary/ezine/caseyhyd2.html (1 of 4) [5/12/2004 11:29:50 PM] Carrying Out Effective Repairs To Hydraulic Cylinders straightness should always be checked when a cylinder is being repaired. This is done by placing the rod on rollers and measuring the run-out with a dial gauge (see exhibit 1). Position the rod so that the distance between the rollers (L) is as large as possible and measure the run-out at the mid- point between the rollers (L/2).

Exhibit 1

top

In most cases, bent rods can be straightened in a press. It is sometimes possible to straighten rods without damaging the hard-chrome plating, however if the chrome is damaged, the rod must be either re-chromed or replaced.

If the chrome surface of the rod is pitted or scored, the effectiveness and service life of the rod seals will be reduced. Minor scratches in the chrome surface can be polished out using a strip of fine emery paper in a crosshatch action. If the chrome is badly pitted or scored, the rod must be either re-chromed or replaced. Machining a new rod from hard-chrome plated round bar, which is available in standard sizes from specialist steel merchants, is usually the most economical solution for small diameter rods.

Before a rod can be re-chromed, the existing chrome plating has to be ground off. Each time a rod is ground, the diameter of the parent metal is reduced and therefore the thickness of the chrome layer required to finish the rod to its specified diameter increases. If the chrome layer is too thick, the chrome will stress crack, resulting in premature failure of the rod seals. Therefore, when the thickness of the chrome plating on a cylinder rod reaches 0.008” the rod must be scrapped.

Head – It is common, in cylinders used in light-duty applications, for the rod to be supported directly on the head material, which is usually aluminum alloy or cast iron. A metallic or non-metallic guide bush (wear band) is fitted between the rod and the head, in applications where there are high loads on the rod. If a cylinder is fitted with a bush between the rod and the head, it should be replaced as part of the repair.

If the rod is supported directly on the head, use an internal micrometer or top

http://www.maintenanceresources.com/ReferenceLibrary/ezine/caseyhyd2.html (2 of 4) [5/12/2004 11:29:50 PM] Carrying Out Effective Repairs To Hydraulic Cylinders vernier caliper to measure the head’s internal diameter. Take measurements in two positions, 90 degrees apart, to check for ovalness. The inside diameter of the head should not exceed the nominal rod diameter plus 0.004”. For example, if the nominal diameter of the rod is 1- 1/2” then the inside diameter of the head should not exceed 1.504”. If the head measures outside this tolerance, it will allow the rod to load the rod seal, resulting in premature failure of the seal. Therefore, the head must be sleeved using a bronze bush or be replaced with a new head, machined from a similar material.

Minor scoring on the lands of the seal grooves inside the head is not detrimental to the function of the cylinder, as long as the maximum diameter across the lands does not exceed the nominal rod diameter plus 0.016”. For example, if the nominal diameter of the rod is 1-1/2” then the inside diameter of the head, measured across the lands of the seal grooves, should not exceed 1.516”. If the seal lands measure outside this tolerance, the service life of the rod seal will be reduced. Therefore, the head must be replaced with a new head, machined from a similar material.

Barrel – Inspect the barrel for internal pitting or scoring. If the barrel is pitted or scored, the effectiveness and service life of the piston seal will be reduced. Therefore, the barrel must be honed to remove damage or be replaced. On small diameter barrels, pitting or scoring less than 0.005” deep can be removed using an engine-cylinder honing tool. The barrel must be honed evenly along its full length.

The maximum bore diameter for standard-size piston seals is the nominal bore diameter plus 0.010”. For example, if the nominal bore diameter of the barrel is 2-1/2” then the maximum size after honing should not exceed 2.510”. This size should be checked at several points along the barrel, using an internal micrometer.

If scoring or pitting is still present at 0.010” oversize, the barrel must be honed further to accommodate oversize seals or be replaced. Manufacturing a new barrel from honed tubing, which is available in standard sizes from specialist steel merchants, is usually the most economical solution for small diameter cylinders.

Large diameter, inch-size cylinder barrels can be salvaged by honing either 0.030” or 0.060” oversize and fitting the corresponding oversize piston seals. Oversize seals for metric-size cylinders have limited availability and top therefore it is not always possible to salvage metric-size barrels by fitting oversize seals.

Piston – The pistons of cylinders used in light-duty applications are usually machined from aluminum alloy or cast iron and operate in direct contact with the cylinder bore. Minor scoring on the outside diameter of the piston is not detrimental to the function of the cylinder, as long as the minimum diameter of the piston is not less than the nominal bore diameter minus 0.006”. This can be checked using an external micrometer. For example, if

http://www.maintenanceresources.com/ReferenceLibrary/ezine/caseyhyd2.html (3 of 4) [5/12/2004 11:29:50 PM] Carrying Out Effective Repairs To Hydraulic Cylinders the nominal diameter of the barrel is 2-1/2” then the minimum piston diameter would be 2.494”. If the piston diameter measures outside this tolerance, it must be replaced with a new piston, machined from a similar material.

Non-metallic wear bands are fitted between the piston and barrel, in applications where there are high loads on the rod. If the cylinder is fitted with piston wear bands, these should be replaced as part of the repair.

Ordering Seals

If you order seals from a seal supplier, avoid the common practice of measuring the old seals. Seals can either shrink or swell in service and in some cases, an incorrect seal may have been installed previously. To ensure that you are supplied with the correct seals, measure all seal grooves with a vernier caliper and give this information to your seal supplier.

Assembly

Thoroughly clean all parts in a petroleum-based solvent and blow-dry using compressed air. Coat all parts with clean hydraulic fluid during assembly. Prior to installing seals, ensure that the seal grooves are clean and free from nicks and burrs. Avoid using a screwdriver or other sharp object when installing seals, as this can result in damage to the seal. After the cylinder has been assembled, plug its service ports to prevent ingress of moisture or dirt.

About the Author: Brendan Casey has more than 16 years experience in the maintenance, repair and overhaul of mobile and industrial hydraulic equipment. For more information on reducing the operating cost and increasing the uptime of your hydraulic equipment, visit his Web site: http://www.InsiderSecretsToHydraulics.com

http://www.maintenanceresources.com/ReferenceLibrary/ezine/caseyhyd2.html (4 of 4) [5/12/2004 11:29:50 PM] Article

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Machinery and Equipment MRO, November 2000

PRACTICAL AUTOMATION

Cylinder mounting dangers

Pay attention to the load-carrying capabilities of fluid power cylinder mountings to prevent their misapplication, or you could end up with premature cylinder failure, serious machinery problems or safety issues

By Ted Grove

Fluid power cylinder manufacturers generally offer a huge assortment of cylinder mounting styles, which is extremely Articles in related categories handy for the machine designer. All too often, however, in their Fluid Power haste to finish their projects, the designers fail to consult the Safety application information sections of the cylinder catalogue they are using and end up selecting the most convenient but Training perhaps the least serviceable mounting for their application. This oversight can result in improper operation of the machine, premature failure of the cylinder or even catastrophic failure of the cylinder or machine, perhaps threatening the personal safety of employees.

Pneumatic cylinders, because of their lower pressures, can generally be used at full pressure, regardless of mounting. Medium and heavy-duty hydraulic cylinders, in some mounting styles, may not be used at full rated pressure.

Cylinder mountings are generally classified into three groups: Group 1 -- Straight-line force transfer with fixed mounts, which absorb force on the cylinder centre line; Group 2 -- Pivot force transfer which absorbs force on the cylinder centre line but allows swivelling in one plane; and Group 3 -- Straight line force transfer with fixed mounts, which do not absorb force on the centre line.

Group 1 includes front and rear flange mount as well as tie rod mount cylinders. Selection of front or rear mounting should be based on whether the cylinder will be used primarily in compression or tension. In compression, the back end of a single-rod cylinder is pressurized. Using a front mount will put undue tension on the tie rods and mounting bolts and generally result in derating the maximum permissible pressure for the cylinder. The same logic can be applied to tension loading with rear-mount cylinders.

Group 2, pivot force cylinders, will normally allow for misalignment in one plane only. The use of spherical bearings in single lug rod and cap clevis mountings will allow for minor misalignment in the second plane. Rear clevis and rear trunion cylinders should only be

http://www.mro-esource.com/issues/ISarticle.a...&story_id=AMRO71813&issue=11012000&PC=&RType= (1 of 3) [5/12/2004 11:29:56 PM] Article

used in shorter stroke applications. In long-stroke applications, the entire weight of the cylinder will be supported by the rod bearing, causing undue wear and damage, especially when extended. Judicial use of stop tubes in the cylinder to prevent full extension can help a little but the best solution is to use a mid-cylinder trunion positioned to optimally balance the load.

Group 3 cylinders are generally described as side-mounted cylinders. They include side lug, end lug, side tapped, and end angle mountings. All of these mountings produce an off- centre or twisting motion to the cylinder structure, which may cause leaks and premature bearing failure. They are, however, convenient and when needed, the side lug design should be selected if possible. The welded or bolted connection points of end lug and end angle mounts will be severely stressed by the rocking action of the end caps and may fail. End- mounted side connections should be avoided in all but the lightest of applications

The off-centre twisting motion can also create structural problems in the machine. The machine base, to which the cylinder is side-mounted, must be strong enough to withstand the resulting eccentric loading without flexing. Any movement of the machine structure at this point will tend to amplify the cylinder misalignment.

Be careful when selecting cylinder mounts. By being competitive in offering a wide range of cylinder mounts, the cylinder manufacturer may be doing himself and his customer a disservice. More emphasis must be placed on the derating factors or load carrying capacities of various mountings to prevent their misapplication. Having said this, however, does little to solve the problem. The onus, as usual, rests on the shoulders of the user. The use of a little common sense and mechanical intuition, as well as referring to the cylinder manufacturers' engineering recommendations when designing a machine, can save you a lot of grief later on.

Ted Grove is corporate training manager for Wainbee Limited, Mississauga, Ont., and an widely experienced fluid power trainer.

Cylinder mountings

Table of Contents

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Application Of Belt Winder For Conveyor Replacements In Coal Handling Plants Of Thermal Power Stations This paper focuses on the application of belt winders for conveyor replacement. A belt winder, which is proposed in this paper, should be designed with proper accessories for replacement of conveyors. The system which is introduced in this paper minimizes time and manpower by developing a system to remove old conveyor and inserting new belting with less time and manpower - requires free Adobe Acrobat Reader for viewing. Basic guide to maintenance benchmarking Benchmarking has become a common practice in all kinds of businesses, but nowhere is it more prevalent than in manufacturing Benchmark definitions Published by the European Federation of National Maintenance Societies

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Benchmarking as a Maintenance Performance Measurement and Improvement Technique Benchmarking is increasingly being viewed as one of a number of important business improvement tools that any organisation should have in its kit bag. In this article, Sandy Dunn of Assetivity (and the webmaster of the Plant Maintenance Resource Center) discusses benchmarking in an equipment maintenance context - requires free Adobe Acrobat Reader for viewing. Data...Data...Data Turning data into useful information is the key to making critical equipment reliable Developing KPIs - requires free Adobe Acrobat Reader for viewing. How to Measure Performance--A Handbook of Techniques and Tools The Training Resources and Data Exchange (TRADE) Performance-Based Management Special Interest Group (PBM SIG) was chartered to foster continuous improvement and facilitate the use of performance-based management techniques within the U.S. Department of Energy (DOE) community.This handbook has been compiled by the PBM SIG to provide reference material to assist in the development, utilization, evaluation, and interpretation of performance measurement techniques and tools to support the efficient and effective management of operations. OEE Industry Standard So What Do You Know About Your Overall Equipment Effectiveness? Standardization of Definitions for Benchmarking The desire to engage in collaborative relationships to gain competitive advantage at a global level was the driver for a proposal by the Surface Mining Association for Research and Technology (SMART) to commission a research project intended to enable comparison of equipment performance across the mining industry. As a start point it was decided to focus on the development of common definitions for availability and utilization.

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Testing Performance Measures within Maintenance A lean manufacturer operating in the automotive sector is currently participating in research that aims to measure performance of the Maintenance function. This paper discusses this research, which has identified a set of performance measures that can be used to analyse the impact of lean thinking within the Maintenance function - requires free Adobe Acrobat Reader for viewing. The Scoreboard for Maintenance Excellence - requires free Adobe Acrobat Reader for viewing. What is the True Downtime Cost? - requires free Adobe Acrobat Reader for viewing.

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A driving lesson for operations and maintenance Picture this. Personnel from a plant are driving along a road in an automobile. The maintenance manager is driving blindfolded. Sitting beside the maintenance manager is the mill manager who is peering in the rear view mirror. In the back seat, the production manager is urging the maintenance manager to proceed at top speed while simultaneously warning him about a flat tire. Backlog Management One of a series of articles on Maintenance Planning basics by Daryl Mather. This article introduces the concept of backlog management. Defining Work Order Priorities There can be no perfect method of defining or establishing work order priority. We can however create some ground rules to assist with this. - requires free Adobe Acrobat Reader for viewing. Determining Spare Parts Requirements Using Repair Scenarios From New Standard Institute Effectively Manage the Preventive Maintenance Backlog

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Essential Elements of Backlog Measurement and Analysis Backlog. What is it? What does it mean? Why bother? These are questions that, surprisingly, have many answers none of which are ever the same or fully complete Failing to Plan Negates Maintenance Efficiency Guideline to Good Practices for Maintenance Planning & Scheduling This guide is intended to assist facility maintenance operations in the review of existing and in developing new programs to ensure maintenance work package planning, scheduling, and coordination identifies all technical and administrative requirements for a work activity and provides the materials, tools, and support activities needed to perform the work. - requires free Adobe Acrobat Reader for viewing. Integrating RCM with Effective Planning and Scheduling Maintenance Management - The Planned State - requires free Adobe Acrobat Reader for viewing. Maintenance Planning and Scheduling Basics A brief "back to basics" outline of the differences between Planning and Scheduling, and some tips for improving performance in this area ME & the Planner/Scheduler Function Manufacturing and Facility maintenance organizations everywhere struggle with the challenge of providing operational capacity for their company or organization. Maintenance strives to accomplish this by increasing the reliability of the equipment or process through effective Preventive Maintenance and effective material and labor budget utilization. The best way to accomplish these efforts is through effective planning and scheduling. Qualified Planner/Schedulers in a proactive, mature, structured, and disciplined maintenance organization can greatly impact the success of meeting these challenges - requires free Adobe Acrobat Reader for viewing. Measuring Backlog Second in a series of articles discussing the management of backlog

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Optimised Production Scheduling for Maximum Plant

Utilisation and Minimum Downtime Organising the Plan for Turnarounds - requires free Adobe Acrobat Reader for viewing. Planning Guide for Maintaining School Facilities The Planning Guide was developed to help readers better understand why and how to develop, implement, and evaluate a facilities maintenance plan. The document is designed for staff at the local school district level, where most facility maintenance is planned, managed, and carried out. This audience includes school business officials, school board members, superintendents, principals, facilities maintenance planners, maintenance staff, and custodial staff. Proactive Approach to Shutdowns Reduces Potlatch Maintenance Costs Potlatch Cloquet's low-cost shutdown management techniques focusing on type, quality, and timing of work contribute to an 83% drop in maintenance cost per ton Refining the Project Planning Process Describes various project planning methodologies. Shut down management for Coal handling plant of thermal power station The critical path method (CPM) or sometimes a Gantt charts is used for planning shut down. But it is observed that existing method is not sufficient and foolproof for such type of work. This paper covers a new method (MUC), which is developed for shut down management of coal handling plant of thermal power stations. - requires free Adobe Acrobat Reader for viewing. Standardising Maintenance Work One of a series of articles on Maintenance Planning basics by Daryl Mather. This article discusses the effective use of Work Order templates. Surviving the Maintenance Shutdown From New Standard Institute

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The Impact of Planning & Scheduling on Paper Machine Shutdown Day The impact that planning & scheduling has on an organization is quite apparent. What is not always so apparent is how planning & scheduling of maintenance on a particular machine impacts the organization. This article discusses the impact of planning on a paper machine's shutdown - requires free Adobe Acrobat Reader for viewing. The Importance of Establishing Priorities The Shutdown Manager's Pre-Shutdown Checklist From New Standard Institute Transparency in Critical Path Method Scheduling Effective project management requires the development of a realistic plan and a clear communication of the plan (from the beginning to the end of the project). The critical path method of scheduling is the fundamental tool used to develop and communicate project plans. Ensuring the integrity and transparency of these schedules is paramount for project success Turnaround Project Planning Primer This handbook was prepared to help those whose responsibilities include the planning and scheduling of process plant turnarounds Work Flow Concepts One of a series of articles on Maintenance Planning basics by Daryl Mather. This article introduces the concept of Maintenance Planning workflow. Work Order Execution and Data Capture One of a series of articles on Maintenance Planning basics by Daryl Mather. This article introduces concepts surrounding getting work done, and recording work order data for later analysis. Work Order Priorities One of a series of articles on Maintenance Planning basics by Daryl Mather. This article introduces the concepts surrounding setting Work Order Priorities.

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2001 Maintenance Task Selection survey results Describes the results of the 2001 survey, run by the Plant Maintenance Resource Center, covering the methods that organizations use to select appropriate PM tasks. Adjustments - Friend or Foe Adjustments are an excellent way to get an equipment set up to standard (ie. Manufacturers specification). They also, however, can be used very effectively to get equipment out of standard. How many times have we seen a situation at shift change where an operator takes over a machine or a line and the first action they take is to change settings even though the machine has been performing well over the previous shift? How many times have we walked past equipment where guards on machine components have nuts missing, holes in machine frames where something should be or places where things should be http://www.plant-maintenance.com/maintenance_articles_rcm.shtml (1 of 13) [5/12/2004 11:37:34 PM] Equipment Maintenance Strategies, Preventive, Predictive Maintenance and Reliability Centered Maintenance (RCM) Articles

attached and are not? Were these issues deliberately left like this or have things gone missing and we just don’t know where or why they have.So what can be done to overcome these issues? - requires free Adobe Acrobat Reader for viewing. Analysis: RCM Versus RCA There is a basic but very real misconception concerning the roles of RCM (Reliability Centered Maintenance) and RCA (Root Cause Analysis) in today’s operating facility. This is due primarily to the fact the most people think that the two programs do virtually the same thing - nothing could be further from the truth. Applying the Predictive Approach From New Standard Institute Best Practice Maintenance Strategies for Mobile

Equipment Beyond Detection - Realizing The Value In A PDM Program This paper gives examples from the power industry to examine the issues that surround this challenge; and, will provide an effective means in which to identify, track, and evaluate the financial benefits associated with anomalies detected in a Machinery Health Management program Building a PM Program - Brick by Brick From New Standard Institute Centrifugal Pump Temperature Rise Operating a centrifugal pump far left on the performance curve results in a significant temperature rise, erosion and cavitation. To avoid these scenarios methods for calculating this rise in temperature, and establishing minimum flow requirements for thermal and mechanical protection are discussed

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Checking Best Practices for Preventive Maintenance Visiting plants in different corners of the world, we often are asked: “What are the current best practices for preventive maintenance (PM)?” We usually answer that we define preventive maintenance using 95 key elements. We also point out, to some people’s dismay, that there is no single silver bullet for improving PM, but rather many combined efforts will be required to eventually yield results. CMMS and Preventive Maintenance A very important part of a cost-effective preventive maintenance program is route-based activity Compressed Air Safety Nets: A Guide To Predictive Maintenance Programs from Ingersoll Rand Condition Based Maintenance and Performance Discusses performance related issues in the development of CBM strategies Condition Based Maintenance For Coal Handling Plant Of Thermal Power Stations How one power station has implemented Condition Based Maintenance to detect the onset of a degradation mechanism thereby allowing casual stresses to be eliminated or controlled prior to any significant deterioration in the component physical state. Guidelines for implementation of Condition Based Maintenance in Coal Handling Plants are also discussed in this paper. - requires free Adobe Acrobat Reader for viewing. Condition Based Maintenance for improving Power Plant Economics States the case for improved use of Condition Based Maintenance in the Indian Power Industry - requires free Adobe Acrobat Reader for viewing.

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Condition Monitoring in the 21st Century This article outlines some of the key business opportunities and issues which are driving change in the industry, summarises some of the resulting trends, and then draws some conclusions regarding the implications of these trends for Condition Monitoring equipment manufacturers and suppliers, Condition Monitoring contractors, and organisations employing Condition Monitoring techniques Condition Monitoring of Smaller ... Less Critical Equipment Provides Major Improvements In Reliability and Lower Maintenance Costs - requires free Adobe Acrobat Reader for viewing. Condition Monitoring of Steam Turbines by Performance Analysis The paper outlines with some examples some condition monitoring techniques which have contributed to running some large machines for up to 17 years without opening high pressure sections Condition-Based Maintenance at Southern California Edison Determining the Frequency of Condition Monitoring tasks A discussion thread from the plantmaint discussion forum Developing PMs for Hydraulic Systems We often accept hydraulic system failure as normal and use resources preparing for failure rather than deciding not to accept hydraulic failure as the norm and strive to eliminate it. In 1980, Kendall Co. changed their focus from reactive to proactive maintenance and practically eliminated unscheduled hydraulic failure - requires free Adobe Acrobat Reader for viewing. Development of an RCM Program The implementation of a Reliability Centered Maintenance or RCM program begins with a solid and practical Preventive Maintenance (PM) program

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Diagnosing a Low-Speed Gearbox Problem: A PREDICT/DLI Case History - requires free Adobe Acrobat Reader for viewing. Do You Listen When Your Equipment Speak to You Do you listen to your motors complaining about overload? Do you see your pump packings crying a flood? Do you hear you bearings whine about contaminated lubricants? Do you notice your steam system that coughs excessive condensate and it’s complains about strained elbows? Examining the Processes of RCM and TPM What do they ultimately achieve and are the two approaches compatible? Frequently Asked Questions On the Mechanical Condition Monitor (MCM) - requires free Adobe Acrobat Reader for viewing. Getting the Most from Predictive Maintenance There are dozens of predictive maintenance technologies, and some have become standards in many industries. Those "standard" technologies include vibration analysis, ultrasound, oil analysis, wear-particle analysis, and thermography. Following are descriptions of the ways maintenance professionals have traditionally used these predictive technologies as well as applications you may not have considered Getting the Most from Predictive Maintenance Hidden Treasure: Eliminating Chronic Failures Can Cut Maintenance Costs Up to 60% courtesy of Reliability Center, Inc. How Good Is Your PM Program? Here is a method for scoring the effectiveness of a preventive maintenance program How To Lube Up Your FMEA Process Get specific about lubrication related problems to step up reliability and achieve lubrication excellence Increasing the Reliability of a System

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Increasing the reliability of a system doesn't necessarily mean spending big bucks or relying on high technology Information and Power in your Hands; Data Collectors Meet Mobile Computing With the advent of high volume, low cost mobile computers and the adoption of digital audio technology, we are now seeing the introduction of the "third generation" data collector. - requires free Adobe Acrobat Reader for viewing. Information Everywhere - Connectivity in the Future of Predictive Maintenance - requires free Adobe Acrobat Reader for viewing. Integrating CMMS with Predictive Maintenance Software - requires free Adobe Acrobat Reader for viewing. Integrating RCM with Effective Planning and Scheduling Integrating Vibration, Motor Current, and Wear Particle Analysis with Machine Operating State for On-line Machinery Prognostics/ Diagnostics Systems (MPROS) - requires free Adobe Acrobat Reader for viewing. Introduction to RCM by John Moubray Is Preventive Maintenance Necessary? Is RCM the Right Tool for You? This article is part of the Reliability Handbook, originally published by PEM magazine in Canada. - requires free Adobe Acrobat Reader for viewing. Maintaining Substation Reliability This article, contributed by Joe Nichols and Bob Matusheski of Meridium, Inc. outlines how one electric utility used Reliability Centered Maintenance principles to develop asset management strategies for their electrical substations. - requires free Adobe Acrobat Reader for viewing. Maintenance Management - A New Paradigm by John Moubray

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Maintenance Method For Critical Equipments Of Coal Handling Plant Developing a special method for maintenance of Critical Equipments is necessary for improving maintenance quality and reducing operating costs. The combination of corrective preventative and condition based maintenance will required to apply for Critical Equipments. This type of maintenance policy and strategy will improve performance of CHP through availability of Critical Equipment. - requires free Adobe Acrobat Reader for viewing. Maintenance Optimization by Integrating Technologies and Process Change This paper describes a process, which may be used to identify existing resources and to specify new technologies necessary to implement an integrated Predictive Maintenance Program. The successful implementation of PdM, coupled with systematic process change will enable organizations to optimize their maintenance programs. The success of this optimization will lead to reduce maintenance costs and operational outages. Maintenance Program Reduces Pulp Loss at Fletcher Challenge Canada At Fletcher Challenge Canada’s Crofton, B.C., pulp mill, a preventive maintenance program stressing teamwork helps avoid breakdowns Maintenance Resources-Optimizing The objective of this research paper is to understand what is Reliability Centered Maintenance (RCM), how it works, identify lessons learned, potential application to the UH-60, Utility Helicopter to improve current system maintenance practices; and the pros and cons involved with its implementation Maintenance Task Selection This 4 part summary from the plantmaint Maintenance discussion forum discusses alternative approaches to Maintenance task selection, including RCM, PM Optimisation (PMO), RCMCost, and others - it also touches on Total Productive Maintenance (TPM) Making PM really work for you http://www.plant-maintenance.com/maintenance_articles_rcm.shtml (7 of 13) [5/12/2004 11:37:34 PM] Equipment Maintenance Strategies, Preventive, Predictive Maintenance and Reliability Centered Maintenance (RCM) Articles

Making PM Really Work for You Management aspects on Condition Based Maintenance While this article draws on experience within the Maritime industry, it is equally relevant to most organizations today. Does the following excerpt sound like your organisation? "Condition monitoring has been introduced...with limited or no success. In most of these cases the condition-monitoring tool has been purchased without considering the necessary change of the organisation...and the need for an organised knowledge transfer." If so, read more - requires free Adobe Acrobat Reader for viewing. Managing Availability for Improved Bottom-Line Results The reliability block diagram is the cornerstone of the availability model because it shows how failure in a plant element affects process uptime Managing Availability for Improved Bottom-Line Results: Part II Closing the gaps between the types of availability in a cost-effective way makes the plant more successful. It requires a thorough understanding of the top-level factors that determine availability and finding ways to improve in each aspect of those factors MCM : A New Technology in Predictive Maintenance MCM (Motor Condition Monitor) is a device that has the capability of detecting impending mechanical and electrical failures in motors and motor based systems at the early stages of fault development. The experimental modelling technology used in MCM can automate fault detection and prevent unplanned machine failures. The paper describes the technology and presents the results of experiments that were done to prove the capability of the MCM device in fault detection Measure Field Reliability with Statistics Misunderstandings about what reliability is and which data is necessary to measure it limit the value of reliability statistics. This article describes reliability prediction and estimation from data required by generally accepted accounting principles.

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Megger on the Move! Optimizing Condition Based Maintenance This article is part of the Reliability Handbook, originally published by PEM magazine in Canada. - requires free Adobe Acrobat Reader for viewing. Optimizing Time Based Maintenance This article is part of the Reliability Handbook, originally published by PEM magazine in Canada. - requires free Adobe Acrobat Reader for viewing. PdM Technology Integration Extends Planning Capability Plant Maintenance Strategy: Key For Enhancing Profitability Proper maintenance of plant equipment can significantly reduce the overall operating cost, while boosting the productivity of the plant. Although many management personnel often view plant maintenance as an expense, a more positive approach in looking at it is to view maintenance works as a profit center. The key to this approach lies in a new perspective of proactive maintenance approach. Predictive maintenance for centrifugal pumps Is there a reliable method of introducing a centrifugal pump predictive maintenance program? Predictive Monitoring of Seal-less Pumps - requires free Adobe Acrobat Reader for viewing. Predictive Technology is the Key to Breaking Error Chains It is virtually impossible for one or even a few human errors to cause a random event (significant failure), no matter how dramatic the event. This small statement has a meaning so powerful that it’s hard to believe that we as humans do not take it to heart. Press maintenance can improve quality, reduce waste Preventive Maintenance strategies for printing presses Preventive Maintenance II Reasons why your PM program might not always work as well as you would like it to work

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Preventive Maintenance III Reasons why your PM program might not always work as well as you would like it to work Preventive Maintenance Optimization A modern and cost-effective approach to preventive maintenance shows that there is no maintenance cost optimum Proactive Maintenance Can Yield More Than A 10-Fold Savings Over Conventional Predictive/Preventive Maintenance Programs Putting Precision Into Proactive Maintenance Precision maintenance does not teach intelligence. It only teaches an intelligent way to make a good job a better one. Precision maintenance is not an option any more. It is a requirement. RCFA + RCM = Formula for Successful Maintenance When these two approaches are properly combined, they materially enhance operating performance. RCM Versus RCA Most people think that the two programs do virtually the same thing - nothing could be further from the truth Reducing the Cost of Preventive Maintenance - requires free Adobe Acrobat Reader for viewing. Reliability Based Logistics versus Reliability Centered Maintenance This paper compares and contrasts Reliability Based Logistics (RBL) and Reliability Centered Maintenance (RCM) and discussed appropriate situations in which to implement each. This paper attempts to reduce the confusion acquisition professionals sometimes exhibit regarding the differences between RCM and RBL. Reliability by the Numbers Statistical reliability approaches focus your efforts on the failure modes that cost the most money, separating the vital few from the trivial many like a laser-guided missile Reliability Revolution Is a new shift in paradigm occurring?

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Reliability-Centered Maintenance and its Meaning to the Oil Analysis Professional Sensors in Condition Monitoring - requires free Adobe Acrobat Reader for viewing. Setting Up and Operating A Cost-Effective Predictive Maintenance Program at Champion Paper Company - requires free Adobe Acrobat Reader for viewing. The Benefits of Predictive Maintenance A-Z The Failure Dilemma How do I move towards Proaction when I work in such a Reactive environment The Future of Machinery Monitoring Technology - requires free Adobe Acrobat Reader for viewing. The Fuzzy Side of Equipment Reliability The Importance of Predictive Maintenance The RCM Trap Reliability Centered Maintenance (RCM) has its place, but many times mills jump into training programs and attempt to implement this concept long before they are ready for it The role of condition monitoring in machinery asset management In the context of production machinery, references to “asset management” are now quite frequent in the literature. Although no precise definition has been offered, the term generally refers to maximizing the economic performance of the machinery. Condition monitoring, including predictive maintenance programs, plays a central role. The role of condition monitoring in machinery asset management In the context of production machinery, references to “asset management” are now quite frequent in the literature. Although no precise definition has been offered, the term generally refers to maximizing the economic performance of the machinery. Condition monitoring, including predictive maintenance programs, plays a central role.

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The Role of the Facilitator in Operational Reliability by José Durán Understanding Hidden Failures in RCM Analyses Addressing hidden failure modes is a key aspect for successfully achieving plant reliability Uptime at Minimum Cost in the Process Industries This paper attempts to share some of the key learning points, realized over a period of twenty years in the Brewing/Paper and Pulp industry with implementation experience at nineteen plants on a wide range of continuous process equipment. Using an Expert System for Precision Machine Tool Diagnostics: A Case Study - requires free Adobe Acrobat Reader for viewing. Utilizing Vibration Monitoring As A Planning Tool For A Predictive Maintenance Program - requires free Adobe Acrobat Reader for viewing. What is Operational Reliability? What is Proactive Maintenance? What is Reliability Centred Maintenance? RCM as a subject has been widely written about and it is not the aim of this paper to provide a detailed account of the process here. Rather, its aim is to provide an introduction to RCM for new users and a quick history for the more experienced. When Does It Pay To Use Reliability Centered Maintenance? All OEM's need to do their own RCM and pass the reliability benefits onto the end users

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Where Is My Data For Making Reliability Improvements? All failure data for plant equipment and processes contains problems with definition of failure, data accuracy, data recording ambiguities, data accessibility, and lack of currency values. This paper argues that these are not reasons for ignoring data - that data analysis puts facts into an action oriented format to focus on making improvements to reduce the cost of unreliability. Finally, it argues that understanding data is helpful, but making cost effective improvements by use of the data is the business objective. - requires free Adobe Acrobat Reader for viewing. Why Shaft Misalignment Continues to Befuddle and Undermine Even the Best CBM and Pro-Active Maintenance Programs Writing the Perfect PM From developing a PM template with example PM template to using RCM tools to determine the frequency of each PM.

http://www.plant-maintenance.com/maintenance_articles_rcm.shtml (13 of 13) [5/12/2004 11:37:34 PM] Maintenance Glossaries of Terms and Articles on Terminology Plant Maintenance Resource Center Maintenance Glossaries of Terms and Articles on Terminology

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A glossary of the terms that are used whenever pollutants are discussed I was given this glossary without an identification of the author. It appears to be a government publication from the Environmental Defense Fund. Acronym Finder A database of more than 91,000 acronyms/abbreviations and their meanings Bearing Glossary of Terms Compressed Air Glossary of Terms The world's largest glossary on the subject of compressed air Compressed Air Glossary of Terms The world's largest glossary on the subject of compressed air Compressed Air Management Glossary The world's largest glossary on compressed air Control Valve Terminology Definition of FMECA Terms George's Glossary of Useful Compressed Air terms Glossary of Concrete Terminology

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Glossary of Maintenance Management Terms Glossary of Pipefitting Terms Glossary of Shaft Coupling Terms Internet Glossary of Pumps Maintenance Terminology - some Key Terms Overview of Infrared Terminology Proposed Maintenance Definitions and Terms Proposed Maintenance Definitions and Terms Reliability Terms Some terms from Reliabiility Center, Inc. Vibration Terminology (Vibrations Institute)

http://www.plant-maintenance.com/maintenance_articles_terminology.shtml (2 of 2) [5/12/2004 11:37:35 PM] Total Productive Maintenance (TPM) Articles Plant Maintenance Resource Center

Total Productive Maintenance (TPM) Articles

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5S: Workplace Organization and Standardization 5S is a process of workplace organization and housekeeping that is carried out gradually and systematically. A well organized workplace motivates people, both on the shopfloor as well as others. It improves safety, work efficiency, improves productivity and encourages ownership. Read more about 5S in this article - requires free Adobe Acrobat Reader for viewing. An introduction to TPM Total Productive Maintenance (TPM) is a concept for maintaining plants and equipment. The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. This article, contributed by Venkat J, offers an introduction to the concepts of TPM Examining the Processes of RCM and TPM What do they ultimately achieve and are the two approaches compatible? From Trouble-maker to Trainer Sometimes "problem" employees can be your biggest asset How to Make TPM Everyone's Priority How to Succeed in TPM Implementation

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Implementing and deploying 5S Read about major steps and hints to successfully implement and deploy 5S in your organization Is Your Implementation Process Going Slower Than Expected? Some of the barriers that slow the implementation processes down Kaizen = Continuous Improvement Maximized Manufacturing Reaps Rewards at Whirlpool-Findlay Operation’s Inspections Drive Reliability Smurfit Stone’s Fernandina Beach facility continues on a long path to reaching world class reliability. In 1999, the mill embarked on a courageous effort to revitalize its reliability program. The mill had a vision of being “world class” and set out on a course to achieve this goal. Powerpoint Presentation about Total Productive Maintenance Principles of 5S Efficient work and quality require clean environment, safety and discipline. 5S are simple, effective rules for tidiness So What Do You Know About Your Overall Equipment Effectiveness? Some important accomplishments to expect from TPM The 5S Philosophy The 5 S's are explained here as a very simplified but thorough and feasible process The 5S Philosophy, hands on! The Cost of NOT Implementing TPM The Right Ingredients for a Successful TPM or Lean Implementation Most or all implementers want our projects to be a success. So, what are the factors that really help this to happen? and we will also ask the opposite question: What are the factors that keep TPM (and other lean projects), from succeeding? The TPM (Total Productive Maintenance) Guide An overview of TPM in a Powerpoint Presentation (available by purchase only) Total Productive Maintenance (TPM) A brief overview of TPM Total Productive Maintenance Case Study MRC Bearings' TPM Journey

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Total Productive Maintenance: Another 3-Letter Program or Real Improvement Process? - requires free Adobe Acrobat Reader for viewing. Total Productive Maintenance: How can it improve your company's bottom line? TPM - I bet an operator can do this! The industry is well aware of the impact of preventive maintenance. With downward cost and price pressure and aging equipment, many plants can barely keep fixing what breaks let alone perform simple equipment inspections with overtime-maxed maintenance people. The solution is clear. Break the vicious circle of reactive maintenance. An obvious resource is to use early detection of problems by an operator. TPM - The Paradigm Movement An excellent index of articles relating to TPM TPM Case Study from MRC Bearings MRC Bearings' TPM Journey: From Totally Painted Machines to Taking Pride in Our Machines TPM History and Implementation TPM Implementation Experiences TPM introduction to Infineon Technologies followed by the chronicle events and experiences learnt in adopting and adapting TPM development activities to improve productivity in DS Business Unit. It also identifies some of the difficulties faced while implementing TPM and finally proposes some solutions for eliminating them. Reviewing the most likely ways that equipment will fail has been a major concern in reliability- centered maintenance (RCM) to ensure that proactive, predictive and preventive maintenance activities during turnaround could be planned and carried out. TPM: Agent of Destruction Uptime at Minimum Cost in the Process Industries This paper attempts to share some of the key learning points, realized over a period of twenty years in the Brewing/Paper and Pulp industry with implementation experience at nineteen plants on a wide range of continuous process equipment.

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Visual Systems for Improving Equipment Effectiveness Imagine reducing your equipment-specific training time by 60 to 70 percent and eliminating equipment errors. It is possible by using some easy techniques, known as "visual systems" or "visual signals" that communicate specific information quickly at the point of use on and near the equipment. W. Edwards Deming - His 14 Recommendations What is Total Productive Maintenance? TPM is a manufacturing led initiative that emphasises the importance of people, a 'can do' and 'continuous improvement' philosophy and the importance of production and maintenance staff working together.

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Bearing and Vibration Analysis Articles

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A New Generation of Condition Monitoring And Diagnostic Systems Recently, a major step forward in the development of microprocessor and signal analysis technology has occurred that allows the development of powerful, efficient, and, at the same time relatively in-expensive systems for continuous condition monitoring of different machine parameters Alignment between the pump and driver In the pump business alignment means that the centerline of the pump is aligned with the centerline of the driver. Although this alignment was always a consideration with packed pumps, it is critical with sealed pumps especially if you are using rotating seal designs where the springs or bellows rotates with the shaft Alignment Pitfalls In theory, machine alignment is a straight- forward process, but in real world applications, it is often compounded by structural faults such as 'soft foot', piping strain, induced frame distortion, excessive bearing clearance or shaft rubs.

http://www.plant-maintenance.com/maintenance_articles_vibration.shtml (1 of 13) [5/12/2004 11:37:38 PM] Bearing and Vibration Analysis Articles

Alignment secrets Flat is better than level when it comes to getting heavy machinery aligned, whether it is a new installation or a new location for old equipment An Introduction to Time Waveform Analysis This paper examines the limitations of the FFT process and identifies specific applications where enhancing FFT information with time waveform analysis is appropriate. - requires free Adobe Acrobat Reader for viewing. Balancing Act Nova Scotia firm helps tame a dancing jaw crusher with vibration analysis, laser alignment and dynamic balancing Balancing of large tandem-compound turbines Ball bearing lubrication in centrifugal pumps It turns out that bearings fail for two main reasons: Contamination of the bearing oil by water or moisture or High heat often caused by too much lubrication Bearing Demodulation / Enveloping Technique A tutorial Bearing fault detection at low speeds - 3 Case studies Bearing fit tolerances Bearing Fit tolerance charts Bearing Knowledge Is Power Bearing Knowledge is Power Bearing Selection (Dynaroll) Calculating Bearing Life (Timken) Centrifugal pump ball bearing seals Bearings are normally lubricated with either oil or grease. Oil mist is another alternative, but recent fugitive emission regulations are making this form of bearing lubrication less desirable Cepstrum Analysis - requires free Adobe Acrobat Reader for viewing.

http://www.plant-maintenance.com/maintenance_articles_vibration.shtml (2 of 13) [5/12/2004 11:37:38 PM] Bearing and Vibration Analysis Articles

Coal Handling Plant Alignment Standards For Shaft To Shaft Alignment Shaft alignment is a technical skill that is not common in the construction and maintenance professions, but categorized more like a specialty. It requires unique and expensive measurement instruments, some calculation capability, and relies heavily on experience for successful results on heavy, high-speed, or high-temperature machines. At present there are no universally accepted standards that define good results. This paper covers alignment standard for Four-dial indicator method. All these standards are developed only on experience basic which are useful for alignments in Thermal Power Station’s Coal Handling Plants. The goal of these standards is to provide the technician with the recommended approach for the quality alignment. 2.0 - requires free Adobe Acrobat Reader for viewing. Common Causes and Cures for Roller Bearing Overheating Condition monitoring and diagnostics of machines Condition Monitoring in the 21st Century This article outlines some of the key business opportunities and issues which are driving change in the industry, summarises some of the resulting trends, and then draws some conclusions regarding the implications of these trends for Condition Monitoring equipment manufacturers and suppliers, Condition Monitoring contractors, and organisations employing Condition Monitoring techniques Condition Monitoring of Steam Turbines by Performance Analysis The paper outlines with some examples some condition monitoring techniques which have contributed to running some large machines for up to 17 years without opening high pressure sections Crankshaft Thrust Bearing Failure - Causes & Remedies Demodulation from June 1999 issue of P/PM. - requires free Adobe Acrobat Reader for viewing. Determination of Balancing Quality Limits - requires free Adobe Acrobat Reader for viewing.

http://www.plant-maintenance.com/maintenance_articles_vibration.shtml (3 of 13) [5/12/2004 11:37:38 PM] Bearing and Vibration Analysis Articles

Determining Accurate Alignment Targets Part three of a four- part series that will cover alignment fundamentals and thermal growth, and highlight the importance of field measurements through two case studies Diagnosing a Low-Speed Gearbox Problem: A PREDICT/DLI Case History - requires free Adobe Acrobat Reader for viewing. Dynamically balancing the pump rotating components Everyone agrees that balancing the rotating components of a centrifugal pump is a good idea, but it is seldom done. Early Warning Fault Detection in Rolling Element Bearings Using Microlog Enveloping - requires free Adobe Acrobat Reader for viewing. Effective Monitoring of Cooling Towers A case study in using vibration analysis to monitor cooling towers at a Potash mine in Canada Effective Preventive Maintenance In 1993, the Skoghall Mill installed extensive on-line equipment for the shock pulse measuring of bearings on Board Machine No. 7 (BM 7). Thanks to this investment, today they can measure,with a focus on wrapping, drying and pressing quantities in the board machine, 1,050 items of stock every 24 hours. Earlier it took between four and six weeks to do the same job. - requires free Adobe Acrobat Reader for viewing. Effects of Shaft Misalignment On Bearing Life Relatively small amounts of shaft misalignment can have a significant impact on the operational life of bearings. Summary of Maintenance and Reliability Center research notes that a 5- mil offset misalignment can reduce expected bearing life by as much as 50 percent in some cases. Eliminating human error in shaft alignment Computer processing and laser measurement update age-old mechanical procedures. Engine Thrust Bearing Failure

http://www.plant-maintenance.com/maintenance_articles_vibration.shtml (4 of 13) [5/12/2004 11:37:38 PM] Bearing and Vibration Analysis Articles

Enveloped Acceleration With the Mechanical Condition Monitor (MCM) - requires free Adobe Acrobat Reader for viewing. Failure Analysis: Contamination How to diagnose contamination failures in bearings Failure Analysis: Corrosion How to diagnose corrosion failures in bearings Failure Analysis: Electrical Fluting How to diagnose electrical fluting in bearings Failure Analysis: Excessive Load How to diagnose excessive load in bearings Failure Analysis: False Brineling How to diagnose false brineling in bearings Failure Analysis: Installation Damage How to diagnose installation damage in bearings Failure Analysis: Loose Fit How to diagnose loose bearing fit Failure Analysis: Lubrication How to diagnose lubrication failures in bearings Failure Analysis: Misalignment How to diagnose misalignment failures in bearings Failure Analysis: Normal Fatigue Failure How to diagnose normal fatigue failures in bearings Failure Analysis: Overheating How to diagnose overheating in bearings Failure Analysis: Preload Failures How to diagnose bearing preload failure Failure Analysis: Reverse Loading How to diagnose reverse loading in bearings Failure Analysis: True Brinneling Failures How to diagnose true brinelling False Brinelling and How to Prevent It

http://www.plant-maintenance.com/maintenance_articles_vibration.shtml (5 of 13) [5/12/2004 11:37:38 PM] Bearing and Vibration Analysis Articles

Five Basic Errors in Shaft Alignment Properly aligned shafts will do more to increase bearing, seal, and rotor life than any other single thing you can do after lubrication. Unfortunately, many maintenance departments in smaller plants still think that alignment is only needed for large, high-speed shafts on somebody else’s equipment Fluid Viscous Damping as an Alternative to Base Isolation Fundamental Considerations for Maintaining Your (Machinery) Balance in an Unbalanced World - requires free Adobe Acrobat Reader for viewing. Ground Vibration Measurement - Case Study The origin of this case study was a series of complaints that all the executives sitting in and around the Senior Vice President’s office were feeling vibrations on the table as well as on the floor. - requires free Adobe Acrobat Reader for viewing. How to Bump Test with the Microlog - requires free Adobe Acrobat Reader for viewing. How Unbalance Affects Bearing Life This short paper, from Ahmed M. Al-Abdan, does exactly what it says - describes how unbalance affects bearing life How Well Do You Know Your Bearings? Use this quick mini- quiz to test your bearing knowledge. Hydraulic Motor Test Bench - Vibration Analysis Case Study Another vibration analysis case study contributed by Madhusudan.N This time, diagnosis is made of a Hydraulic Motor Test Bench, which is experiencing high levels of vibration. - requires free Adobe Acrobat Reader for viewing. Integrating Vibration, Motor Current, and Wear Particle Analysis with Machine Operating State for On-line Machinery Prognostics/ Diagnostics Systems (MPROS) - requires free Adobe Acrobat Reader for viewing. Is Your Equipment Feeling a Little Out of Kilter? Here’s a Little Lesson on Soft Foot What is soft foot? One of the most overlooked machine problems, soft foot describes a machine’s foot that deflects a small amount when the hold- down bolt is tightened.

http://www.plant-maintenance.com/maintenance_articles_vibration.shtml (6 of 13) [5/12/2004 11:37:38 PM] Bearing and Vibration Analysis Articles

Keeping Machinery Alignment Records Keeping Machinery Alignment Records Laser alignments not as simple as they seem Unusual machinery operating characteristics, such as thermal growth, mean that operator knowledge and experience are essential for good results Let's Integrate Oil Analysis and Vibration Analysis Listening for Trouble Portable acoustic emission instrumentation can detect bearing defects down to 0.25 rpm - - that's four minutes per revolution -- well beyond the capabilities of conventional analysis systems used in machinery condition monitoring Magnitude and Phase Monitoring for Determining Shaft Cracks and Other Defects on Large Rotors - requires free Adobe Acrobat Reader for viewing. Measurement and Analysis A short on-line course Mechanical vibration and shock Moisture - The Second Most Destructive Contaminant, And Its Effect On Bearing Life Mounting of Rolling Bearings New life for old anti-friction bearings Certain bearings can be remanufactured to perform like new ODS, Modal, and SDM techniques for solving complex machine or structural problems This article explains some of the differences in these techniques. Orbits, Phase Measurements, and How To Measure Relative Phase - requires free Adobe Acrobat Reader for viewing. Photographs of Machinery Damaged by Stray Shaft Currents Picking bearings off a tree Wooden bearings have been supporting rotating shafts successfully for thousands of years and will continue to do so in the future

http://www.plant-maintenance.com/maintenance_articles_vibration.shtml (7 of 13) [5/12/2004 11:37:38 PM] Bearing and Vibration Analysis Articles

Polymer Bearings in Dryer Section Reduce Failures at Graphic Packaging his case study discusses how Graphic Packaging Corp. reduced equipment-related downtime by replacing old journal bearings with new, nonmetallic bearings on one of its two boxboard machines. The switch has resulted in a reduction in the number and frequency of bearing failures - requires free Adobe Acrobat Reader for viewing. Power Plant Primer Vibration Monitoring This is written to describe the type of machinery that can be found in a typical fossil fuel (gas, oil or coal-fired) electric generating plant to better understand what type of instrumentation is being used for vibration monitoring Premature failure detection by utilizing multiple PdM technologies in a complex gear problem This article includes a diagram of an 8000 KW single reduction gear box, used to transmit power from a 11 KV 6pole motor to a heavy duty melt pump in a HD Polyethylene plant. The machine is considered to be the most vital and critical to the unit and is in continuous service. In late 2001 during routine vibration survey, symptoms of incipient gear wear were detected based on the spectral analysis. Subsequently lub oil analysis also indicated a constant rising trend in the 'Fe' content level. The machine was placed under continuous monitoring for further evaluation. A very precise vibration analysis in conjunction with oil analysis helped to detect a potentially serious gear defect in a very early stage, which initiate an early action plan because the acquisition of a new gear unit would require a minimum time delay of 8 months. A visual inspection revealed misalignment symptoms along with unequal wear pattern on the pinion teeth. Gear teeth were dressed by polishing the tooth profile. Luckily the wear was not excessive and had not crossed beyond the case hardened area of the teeth. A close health monitoring schedule along with periodic visual inspection was initiated till the acquisition of a new gear box. Late fault detection would have cost the Poly Ethylene unit production loss worth many millions of dollars

http://www.plant-maintenance.com/maintenance_articles_vibration.shtml (8 of 13) [5/12/2004 11:37:38 PM] Bearing and Vibration Analysis Articles

Pump bearings, why do they fail? Most of us change the bearings every time we disassemble the equipment to replace the mechanical seal or the packing sleeve. Is this really a sensible thing to do? Questions and Answers About Enveloping... - requires free Adobe Acrobat Reader for viewing. Questions and Answers About SEE Technology - requires free Adobe Acrobat Reader for viewing. Rebalancing Using Influence Coefficients - requires free Adobe Acrobat Reader for viewing. Reducing Bearing Failures Implementing these common sense methods and practices will save time and effort, and lower costs Reduction of Shock Response Spectra Using Various Types of Shock Isolation Mountings Reliability Engineering Snapshot - Vibration Subtle changes in a vibration waveform can help pinpoint problems. Resonant Frequency vs. Low Frequency Noise vs. Q-Control - requires free Adobe Acrobat Reader for viewing. Reverse Rim Dial vs Rim Face The two most common dial indicator alignment methods are the rim-face and reverse rim dial methods. - requires free Adobe Acrobat Reader for viewing. Rolling Bearing Fundamentals Rolling Bearing Shaft and Housing Fits Rolling Element Bearing Acceptance and Life Testing An interesting (and patented) approach to permit the estimation of the life remaining in Rolling Element bearings - requires free Adobe Acrobat Reader for viewing. SEE vs. Traditional Vibration? - requires free Adobe Acrobat Reader for viewing. Setting Turbine Thrust Bearings

http://www.plant-maintenance.com/maintenance_articles_vibration.shtml (9 of 13) [5/12/2004 11:37:38 PM] Bearing and Vibration Analysis Articles

Shaft Eccentricity and Bearing Forces A case study from the petrochemical industry, illustrating how vibration analysis was able to detect shaft eccentricity as a result of improper installation. - requires free Adobe Acrobat Reader for viewing. Shaft To Shaft Alignment By Four-Dial Gage Method For Coal Handling Plant This paper covers Four-dial gage method, which overcome all typical reasons of unsuccessful and difficult alignments, which are observed in Thermal Power Station’s Coal Handling Plants. The goal of this method is to provide the technician with the recommended approach for the quickest way with quality alignment. - requires free Adobe Acrobat Reader for viewing. Shock Pulse goes Spectrum SPM Instrument AB, Sweden, launches a brand new diagnostic method in connection with Leonova™, a hand-held machine condition analyzer. Called the SPM Spectrum™, it is the result of an FFT on the time signal recorded with an SPM shock pulse transducer from a rolling element bearing. The individual bearing frequencies (BPI, BPO, 2*B2 and FT) and their harmonics are highlighted in the spectrum. - requires free Adobe Acrobat Reader for viewing. Signal Processing for Manufacturing and Machine Monitoring National Science Foundation Workshop Simple Ways to Prevent Vibration Spark Erosion Excessive residual magnetism and other rotating equipment problems may lead to spark erosion (EDM). EDM (electrical discharge machining) seriously damages pinion journals, thrust collars, thrust faces, and bearings or seals of high speed and other rotating equipment. Specifying Shaft Alignment Draft standard specifies alignment results, allowing aligner to choose the most appropriate method and instrumentation Specifying Shaft Alignment Draft standard specifies alignment results, allowing aligner to choose the most appropriate method and instrumentation. Synchronous Time Averaging/Machine Balancing - requires free Adobe Acrobat Reader for viewing. http://www.plant-maintenance.com/maintenance_articles_vibration.shtml (10 of 13) [5/12/2004 11:37:38 PM] Bearing and Vibration Analysis Articles

Tarrant Regional Water District Satisfies Growing Production Demands Using Advanced Reliability Tarrant's SCADA Operations Manager, Boyd Miller, believed that vibration monitoring be more effective and performed more efficiently if integrated into the SCADA. Therefore, Tarrant partnered with Emerson to implement a centralized online vibration monitoring system for all high-capital equipment Temperature’s Effects on Mounted Bearings The ABC's of Machinery Vibration Transducers - requires free Adobe Acrobat Reader for viewing. The Benefits Of Implementing A Vibration Analysis And Equipment Deficiency Program The Case For and Against Integration (of Machinery Vibration Signals) - requires free Adobe Acrobat Reader for viewing. The Importance of Shaft Alignment The reasons for premature bearing failure Bearings have no wearable surfaces, they are instead designed to fatigue after many hours of service The Straight Goods on Alignment Dancing with a soft foot: How laser systems can help fix machinery alignment problems. Guidelines for choosing laser alignment systems. Triaxial Vibration Spectral Data - An Important Ingredient for Proper Diagnosis - requires free Adobe Acrobat Reader for viewing. Trouble Shooting Accelerometer Installations Understanding Shaft Alignment: Identical Machines Last article of a four-part series covering alignment fundamentals and thermal growth, and highlighting the importance of field measurements through two case studies Understanding Shaft Alignment: Thermal Growth Part two of a four-part series that will cover alignment fundamentals and thermal growth, and highlight the importance of field measurements through two case studies

http://www.plant-maintenance.com/maintenance_articles_vibration.shtml (11 of 13) [5/12/2004 11:37:38 PM] Bearing and Vibration Analysis Articles

Understanding Shaft Alignment:Basics Part one of a four-part series that will cover alignment fundamentals and thermal growth, and highlight the importance of field measurements through two case studies Using Modal Analysis to Lengthen Bearing Service Life - requires free Adobe Acrobat Reader for viewing. Using Ultrasound with Vibration Analysis to Monitor Bearings In the past, ultrasound and vibration technologies have been used independently to monitor ball bearings in plant equipment. However, it is becoming more common to use ultrasonic inspection interfaced with vibration analysis to spport predictive maintenance programs for periodic inspection of critical bearings to monitor wear and predict failure Using Vibration Analysis to Grease Motors? Using Vibration Monitoring Equipment for Other Functions Utilizing Vibration Monitoring As A Planning Tool For A Predictive Maintenance Program - requires free Adobe Acrobat Reader for viewing. Various Technical Articles on Vibration Analysis and Bearings Vibration Analysis and Predictive Maintenance Programs for Large Rotating Equipment This White Paper organizes and presents some facts about machinery vibration analysis and explodes some popular myths. Vibration Analysis On a Conveyor Drive Unit A Case Study Vibration Analysis on a Conveyor Drive Unit - A Case History - requires free Adobe Acrobat Reader for viewing. Vibration Aspects of Reliability Enhancement via HALT, ESS and HASS What are those acronyms all about? A short online course. Vibration Chart & Formulae Vibration in a centrifugal pump - causes and cures It is necessary to be interested in vibration because it has a major affect on the performance of your pump

http://www.plant-maintenance.com/maintenance_articles_vibration.shtml (12 of 13) [5/12/2004 11:37:38 PM] Bearing and Vibration Analysis Articles

Vibration measurement and diagnosis of valve seat generating machine Another vibration analysis case study contributed by Madhusudan.N This time, diagnosis is made of a Valve Seat Generating machine, which is experiencing problems with manufacturing accuracy, and high levels of vibration. - requires free Adobe Acrobat Reader for viewing. Vibration Transducer Mounting (What You Don't Know Might Hurt You) - requires free Adobe Acrobat Reader for viewing. Voting Thrust Measurements with Other Parameters What Are Enveloping and SEE? - requires free Adobe Acrobat Reader for viewing. What is Resonance all about? Why discuss resonance? Because unless resonance is involved, vibration never causes any damage. Also, many people define the study of vibration as the study of resonances. A short on-line course. White Noise - requires free Adobe Acrobat Reader for viewing. Why alignment checks must be repeatable Technique is proven when portable laser alignment device reduces chain drive trouble on an offshore oil platform Why Engine Thrust Bearings Fail Why Synchronous Time Averaging - requires free Adobe Acrobat Reader for viewing.

http://www.plant-maintenance.com/maintenance_articles_vibration.shtml (13 of 13) [5/12/2004 11:37:38 PM] Technical Articles - Compressor Maintenance Plant Maintenance Resource Center

Technical Articles - Compressor Maintenance

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Articles on Compressors

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15 Rules on Condensation Compressorwise has conducted a substantial amount of research on compressed air systems. There are very few things that can cause more trouble than the condensation that accumulates in the system. This article is a summary of the most important tips relating to this issue Analyzing Reciprocating Compressors Compressor analysis applies data acquisition and analysis technologies to identify, predict, and prevent compressor faults, and to improve compressor performance. RECIP-TRAP® can determine which faults are most severe, calculate a fault's economic impact, and determine key compressor performance characteristics. Choose Portable Compressors With Design Margin Compressor Rod Motion Software Reciprocating compressors usually have rider bands to minimize wear of the piston rings and to eliminate cylinder liner damage due to contact between the piston and the cylinder. Rod motion monitoring detects rider band wear while the compressor is running and allows you to plan maintenance before the piston makes contact with the cylinder.

http://www.plant-maintenance.com/maintenance_articles_compressors.shtml (1 of 3) [5/12/2004 11:37:39 PM] Technical Articles - Compressor Maintenance

Controlling leaks in compressed air systems Most leak control programs are short lived because of the temporary nature of the improvement and the difficulty of quantifying the value of the repairs. To effectively control leaks on a long- term basis, you need to understand why the leaks reoccur with such persistence. Energy Savings in Compressed Air Systems Getting the Most for Your Money - How to Select and Protect Your Air Compressor Investment How to remove water from air lines Part 2 of this series examines the problem of water condensation in compressed air systems as well as other impurities such as compressor oil Improving Reciprocating Compressor Valve Life The key to long valve life is to have positive action of the sealing components with minimum resistance Integrated Automation and Diagnostics for Reciprocating Machinery An integrated automation and diagnostic system will revolutionize the way engine and compressor units are operating Keeping compressed air dry Air systems without compressed air dryers severely restrict the life expectancy of any equipment they operate Leaky Shaft Seals Many people operate rotary screw compressors with oil seeping from around the shaft. This housekeeping nuisance and waste of expensive oil can be avoided with a better understanding of the shaft seal. Managing Compressed Air Energy Part I: Demand Side Issues Data from more than 250 plants show how compressed air energy may be distributed among key usage categories. Use this information to help decide where energy management solutions should be applied first

http://www.plant-maintenance.com/maintenance_articles_compressors.shtml (2 of 3) [5/12/2004 11:37:39 PM] Technical Articles - Compressor Maintenance

Operation and Maintenance of Compressor Valves The suction and discharge valves are key parts of every reciprocating compressor. Valve failure is the single most reason for a scheduled or unscheduled shut down. This article from Andreas Cronenberg of MT Sealing Technology Inc compares alternative valve designs and their performance and maintenance. - requires free Adobe Acrobat Reader for viewing. Regaining Control of Controls Compressor control systems are a common cause of wasted energy. However, it takes more than an understanding of controls to correct the problem and recover the energy savings. A case study of how an air audit assisted one organisation to reduce their energy consumption on their air compressors by over 20% Rotary Screw Compressor Winterizing Tips Solving moisture problems in compressed air systems Part 1 of this new series examines the relationships among air, moisture, pressure and temperature

http://www.plant-maintenance.com/maintenance_articles_compressors.shtml (3 of 3) [5/12/2004 11:37:39 PM] Electrical Articles Plant Maintenance Resource Center

Electrical Articles

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Articles on Electrical Equipment

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A New Approach to Maintaining Process Control Field Devices Adding microprocessors to field instruments has transformed them into data acquisition systems and transmission terminals. Now technicians can use well-designed software to see what is happening inside plant instrumentation A Summary of AC Induction Motor Monitoring - requires free Adobe Acrobat Reader for viewing. Audit of key data is essential for electrical equipment Critical plant electrical equipment may be unfixable by maintenance teams if the required information is not readily at hand. An audit to collect all the needed data will help shorten shutdowns and diminish downtime Choosing the right fieldbus How do you find the ideal fieldbus for your needs? There is no single fieldbus that can fulfill all requirements for every application. There can be considerable differences in communication requirements for different applications, therefore the fieldbus must be selected according to certain requirements Controlling the speed of electric motors The pros and cons, costs and efficiencies of various drive technologies for automation applications

http://www.plant-maintenance.com/maintenance_articles_electrical.shtml (1 of 5) [5/12/2004 11:37:40 PM] Electrical Articles

Creating Reliable Electrical Connections Cleaning, filing, and abrading surfaces are among the options Curbing repeat motor failures How Norfolk Southern Railway got control over short-term motor failures Drives up to challenge of chemical plant The movement of tons of different materials places tough demands on motor controls, which must be able to change motor speeds over a constantly expanding capacity range Electric Motor Monitoring With Your Microlog - requires free Adobe Acrobat Reader for viewing. Electric Motors: Repair or Replace? How to evaluate the variable factors in a repair or replace decision when electric motor troubles strike Electrical Safety Basics Following these safety principles can provide a safer work environment Electrical Tricks of the Trade Tricks of the Trade are very practical ideas that will save you time and a little frustration Electronic Drives Technical Tips - Hot Spares and Load Testing One suggestion we often make regarding critical applications is keep your spare drive powered up! Extend Motor Life with Improved Bearing Care Flux Diagnostics Electric motors convert electrical energy into mechanical energy. In the most common type of electric motor, AC induction, electric power is not conducted to the rotor directly, but receives its power inductively. The construction and operational weaknesses of induction motors are dominated by this principle. This article addresses specific frequencies of interest when performing flux diagnostics Focus on Energy Efficiency Harmonic Discord: Preventing harmonic problems caused by Variable Speed Drives Helping Motors Keep Their Cool How serial comms can save thousands By adopting serial communications, a typical installation in say, a paper mill, can save more than $23,000 over a hard-wired solution. This example explains how

http://www.plant-maintenance.com/maintenance_articles_electrical.shtml (2 of 5) [5/12/2004 11:37:40 PM] Electrical Articles

How to install a drive system successfully Why you need to read the manual, use the right tools and take your time How to Set Up and Use Your Microlog Data Collector/Analyzer for Motor Current Analysis - requires free Adobe Acrobat Reader for viewing. Integrating Vibration, Motor Current, and Wear Particle Analysis with Machine Operating State for On-line Machinery Prognostics/ Diagnostics Systems (MPROS) - requires free Adobe Acrobat Reader for viewing. Managing with motor moisture Tips and hints to keep electric motors dry and extend their operating life. MCM : A New Technology in Predictive Maintenance MCM (Motor Condition Monitor) is a device that has the capability of detecting impending mechanical and electrical failures in motors and motor based systems at the early stages of fault development. The experimental modelling technology used in MCM can automate fault detection and prevent unplanned machine failures. The paper describes the technology and presents the results of experiments that were done to prove the capability of the MCM device in fault detection Megger on the Move! Merging AC drives & fieldbus technology The growing use of fieldbus technology in AC drive installations could save industry considerable costs. But just what are the considerations that you need to make when choosing fieldbus for your application? Gert- Jan Nijmolen, technical product manager, fieldbus modules, ABB, offers some practical advice. NFPA 70E Electrical Standard for Electrical Safety Requirements for Employee Workplaces NFPA 70E addresses electrical safety requirements for employee workplaces that are necessary for the practical safeguarding of employees in their pursuit of gainful employment

http://www.plant-maintenance.com/maintenance_articles_electrical.shtml (3 of 5) [5/12/2004 11:37:40 PM] Electrical Articles

NFPA 70E Electrical Standard for Electrical Safety Requirements for Employee Workplaces - Part 1 of 2 NFPA 70E, addresses electrical safety requirements for employee workplaces that are necessary for the practical safeguarding of employees in their pursuit of gainful employment Overheating Electric Motors: A Major Cause of Failure On-line technologies permit assessment of the entire motor system to facilitate troubleshooting Persistence needed to track TV/radio Interference When a complaint is about TV interference or the inability to get a specific radio channel, a specialist must be assigned to the case. New York State Electric & Gas Corp (NYSEG) relies heavily on ultrasonic technology Powering up motor efficiency Can an energy-efficient motor be rewound without reducing its efficiency? Protecting Mission Critical Electronics Using power conditioning, surge protection, and grounding provides a defense against the disruption, degradation, and destruction of mission critical electronic equipment Revitalizing an Aging Grounding System Checking, testing, and updating installations improves overall electrical parameters Selecting the correct horsepower motor Electric motors operate at their best power factor and efficiency when fully loaded so you do not want to purchase a motor that is too big, and common sense dictates that one that is too small is even worse. In the following paragraphs we are going to learn how to select the correct motor for your centrifugal pump application Solving Motor Failures Due to High Peak Voltages and Fast Rise Times Temperature’s "Shocking" Effect on Electrical Control Systems The Trouble with Torque in Electrical Connections Torque and force are not the same

http://www.plant-maintenance.com/maintenance_articles_electrical.shtml (4 of 5) [5/12/2004 11:37:40 PM] Electrical Articles

The True Cost of COTS The sure sign of momentum is when a movement acquires its own acronym. The current enthusiasm for commercial off the shelf technology is known as COTS, and one avionics expert suggests it may be prudent to rein in the present enthusiasm Track Corona Discharges with Ultrasonic Detector Ultrasound detectors perfectly complement infrared instruments for the routine examination of electrical equipment. While infrared inspections allow operators to detect light that the eye cannot see, ultrasound allows them to detect sounds that the ear cannot hear. Troubleshooting Variable Speed AC Motor Drives VFD Drive Technology Can Save Over 30% In Energy Costs Now that AC variable speed drives have become so accepted into the industrial market, the potential for retrofits and new installations remains very high.

http://www.plant-maintenance.com/maintenance_articles_electrical.shtml (5 of 5) [5/12/2004 11:37:40 PM] Failure Analysis Articles Plant Maintenance Resource Center

Failure Analysis Articles

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Articles on Failure Analysis

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2001 "Root Cause Analysis" Survey Results This survey of use of Root Cause Analysis techniques by Maintenance professionals was conducted on the Plant Maintenance Resource Center web site in late 2000 2003 Blackout (Northeastern US/Ontario) - Reference and Analysis Numerous links to description and analysis of this significant power blackout A Case Study-Failure of Motor Shaft Of Rotary Wagon Tippler -Reasons and Remedy To avoid such type of failure the reason for shaft failure is discussed in this paper. And this paper also suggested necessary precautions to avoid such type of breakdown. - requires free Adobe Acrobat Reader for viewing. A little bit more about troubleshooting centrifugal pumps and mechanical seals One of the U. S. based Japanese automobile manufacturers has a unique method of troubleshooting any type of mechanical failure. The system is called the "Five Whys".

http://www.plant-maintenance.com/maintenance_articles_failure.shtml (1 of 10) [5/12/2004 11:37:41 PM] Failure Analysis Articles

Analysis: RCM Versus RCA There is a basic but very real misconception concerning the roles of RCM (Reliability Centered Maintenance) and RCA (Root Cause Analysis) in today’s operating facility. This is due primarily to the fact the most people think that the two programs do virtually the same thing - nothing could be further from the truth. Analyzing Semiconductor Failure Become an Equipment Reliability Detective courtesy of Reliability Center, Inc. Chronic Events: Panning For Gold Columbia Accident Investigation Board - Final Report The Columbia Accident Investigation Board's final report on the causes of the Feb. 1, 2003 Space Shuttle accident (caution - this is a BIG file - 11Mb) - requires free Adobe Acrobat Reader for viewing. Crankshaft Thrust Bearing Failure - Causes & Remedies Creating the Environment For RCA To Succeed The one thing we should always be cognizant of is the fact that no matter what the new initiative is, it will likely be viewed from the end user as the "program-of-the-month." Dynamic Properties of Damaged Materials Eli Lilly Incident Profile - Finding the Root Cause Root Cause Failure Analysis (RCFA) methodology and a relatively new software program PROACT® were used to get to the incident’s root cause. Engine Thrust Bearing Failure Failure Analysis of Mechanical Components In more than 90 percent of industrial cases a trained person can use the basic techniques of failure analysis to diagnose the mechanical causes behind a failure, without having to enlist outside sources and expensive analytical tools like electron microscopes. Then, knowing how a failure happened, the investigator can pursue the human roots of why it happened. There are times, however, when 90 percent accuracy is not good enough. When personal injury or a large loss is possible, a professional should guide the analysis.

http://www.plant-maintenance.com/maintenance_articles_failure.shtml (2 of 10) [5/12/2004 11:37:41 PM] Failure Analysis Articles

Failure Analysis/Problem Solving Methods courtesy of Reliability Center, Inc. Failure Analysis: Contamination How to diagnose contamination failures in bearings Failure Analysis: Corrosion How to diagnose corrosion failures in bearings Failure Analysis: Electrical Fluting How to diagnose electrical fluting in bearings Failure Analysis: Excessive Load How to diagnose excessive load in bearings Failure Analysis: False Brineling How to diagnose false brineling in bearings Failure Analysis: Installation Damage How to diagnose installation damage in bearings Failure Analysis: Loose Fit How to diagnose loose bearing fit Failure Analysis: Lubrication How to diagnose lubrication failures in bearings Failure Analysis: Misalignment How to diagnose misalignment failures in bearings Failure Analysis: Normal Fatigue Failure How to diagnose normal fatigue failures in bearings Failure Analysis: Overheating How to diagnose overheating in bearings Failure Analysis: Preload Failures How to diagnose bearing preload failure Failure Analysis: Reverse Loading How to diagnose reverse loading in bearings Failure Analysis: True Brinneling Failures How to diagnose true brinelling Failure Codes and their use Request this free article from this link Failure Information Survey Results - requires free Adobe Acrobat Reader for viewing.

http://www.plant-maintenance.com/maintenance_articles_failure.shtml (3 of 10) [5/12/2004 11:37:41 PM] Failure Analysis Articles

Failure Mechanisms and Effects Laboratory - The Impact of Failure Analysis on Engineering Practice In a taped interview with Dr. John H. Smith of the Metallurgy Division, National Institute of Standards and Technology, Gaithersburg, Maryland, Dr. Smith discusses how failure analysis in the field often impacts Engineering Standards. Using slides Dr. Smith discusses and illustrates two specific cases where this has happened. The first of these cases involved the failure of an oil storage tank that was relocated from Cleveland to Pittsburgh. The other case involved the failure of a compressed natural gas trailer tube in Litchfield, Kentucky. In each of these cases, compliance with existing construction and/or building codes failed to prevent failures that ultimately resulted in serious consequences. Failure Modes & Effects Analysis - A Modified Approach courtesy of Reliability Center, Inc. Fighting Failure It is time to change our paradigm to a culture where failure is the exception and certainly not the rule. This is easy to say but a bit more of a challenge to accomplish. Ken Latino of Meridium, Inc. outlines some steps you can take to generate a more Reliability-focused culture within your plant or facility. - requires free Adobe Acrobat Reader for viewing. General Aviation Maintenance-Related Accidents report This report, issued by the Office of Aerospace Medicine within the Federal Aviation Administration in the USA, analyzes 10 years of National Transportation Safety Board data. Its primary conclusion was that installation errors were the leading cause of maintenance-related general aviation accidents. Are there lessons that can be learnt for general industry? - requires free Adobe Acrobat Reader for viewing. How Can Vendor's PROACT to their Customer's Concerns? courtesy of Reliability Center, Inc. How Has Root Cause Failure Analysis Failed To Meet It's Potential? courtesy of Reliability Center, Inc.

http://www.plant-maintenance.com/maintenance_articles_failure.shtml (4 of 10) [5/12/2004 11:37:41 PM] Failure Analysis Articles

How To Select the "Right" Root Cause Failure Analysis (RCFA) Methodology & Vendor courtesy of Reliability Center, Inc. How to sell Root Cause Analysis (RCA) to Management Human Precision: The Human Side of Reliability Reliability in terms of a human being can best be measured by the precision the individual puts into the task being performed. Interim Report: Causes of the August 14th, 2003 Blackout in the United States and Canada The official interim report of this event produced by the U.S.-Canada Power System Outage Task Force Is Analysis An Engineering Function? courtesy of Reliability Center, Inc. Justifying Root Cause Analysis Make the business case with a significant calculated return on investment Justifying Root Cause Analysis Make the business case with a significant calculated return on investment Managing Failure Analysis To be a good failure analyst one must also be a good manager. National Transportation Safety Board Maintenance Accident Report Infobase Contains twenty-four accident investigation reports. The reports included in this reference all have maintenance as a contributing factor in the cause of an aircraft accident O Processo de Análise de Causas Raíz PROACT â Metodologia & Software Através da historia o homem inventou e melhorou numerosos equipamentos e processos baseando-se em suas habilidades para atender uma demanda crescente de produtos e serviços por parte da sociedade. Como resultado desta demanda em crescimento e da otimização de custos, tem-se desenvolvido diversas técnicas Para a análise dos problemas que surgiram nos quipamentos e processos e no rendimento de capacidades, “em um esforço para assegurar a confiabilidade. A Análise por Causa Raiz (ACR) é uma destas armas no arsenal da confiabilidade…

http://www.plant-maintenance.com/maintenance_articles_failure.shtml (5 of 10) [5/12/2004 11:37:41 PM] Failure Analysis Articles

Phoenix Approach Analysis of Ski Lift Strangulation - requires free Adobe Acrobat Reader for viewing. Photographs of Machinery Damaged by Stray Shaft Currents Predictive Technology is the Key to Breaking Error Chains It is virtually impossible for one or even a few human errors to cause a random event (significant failure), no matter how dramatic the event. This small statement has a meaning so powerful that it’s hard to believe that we as humans do not take it to heart. Preventing Space Shuttle Disasters Means Getting to the Root Cause The Space Shuttle Columbia disaster was barely an hour old and already the pundits were speculating about the “cause.” This article argues that no disaster like the Columbia is ever because of one, or even two easy to identify causes, such as the often-mentioned insulation falling and damaged left wing tiles. The root causes always go much deeper. - requires free Adobe Acrobat Reader for viewing. PROACT® for Infrared Thermographers The use of Infrared Thermography puts us all in the position of being “failure analysts”. Our roles sometimes require us to not only to identify thermal anomalies, but also to investigate where the anomaly originates. We will explore how a Root Cause Analysis (RCA) method called PROACT® can help thermographers provide a competitive edge by providing their clients with a Root Cause Analysis in addition to the Infrared Study. The use of PROACT® software will be demonstrated to show how to involve and present the RCA findings to the end client. PROACT® Root Cause Analysis online presentation RCA in Action: The Space Shuttle Columbia Investigation As is typical in our manufacturing organizations, oftentimes it takes high visibility events with catastrophic consequences for a full-blown Root Cause Analysis (RCA) to be conducted. RCFA + RCM = Formula for Successful Maintenance When these two approaches are properly combined, they materially enhance operating performance.

http://www.plant-maintenance.com/maintenance_articles_failure.shtml (6 of 10) [5/12/2004 11:37:41 PM] Failure Analysis Articles

RCFA Provides Whirlpool Corporation with Immediate Improvements This RCFA case study comes from the Marion Division, and was performed two weeks after initial RCFA Methods training was completed. RCM Versus RCA Most people think that the two programs do virtually the same thing - nothing could be further from the truth Recurring Causes of Recent Chemical Accidents The US Environmental Protection Agency (EPA) and the Occupational Safety and Health Administration (OSHA) have investigated recent accidents at petroleum refineries, chemical manufacturing facilities, tolling operations, chemical distributors, and other types of facilities. Recurring causes of these accidents include inadequate process hazards analysis, use of inappropriate or poorly-designed equipment, inadequate indications of process condition, and others Reliability Engineering Snapshot - Machine Design "Rules of Thumb" are just that, general guidelines that need to be reviewed on an individual basis. Not to do so, can spell trouble. A case in point for "making the pinion gear harder than the ring gear." How much harder? Reliability Engineering Snapshot - Material Properties Is it a casting crack or is it a brittle failure? Grain growth pattern versus crack path, which came first? Report into the Auckland Power Failure Root Cause Analysis - Quality of Process? - Part 2 Root Cause Analysis - Quality of Process? - Part 3 When most people conduct their version of a Root Cause Analysis (RCA), where do they usually stop? How do they know when they are done? How do they know that the problem will not recur? Root Cause Analysis: Quality of Process - Part 1 We have all heard the term Root Cause Analysis (RCA) and we likely all interpret its meaning in a different fashion Root Cause Analysis: Will It Find the Weak Link?

http://www.plant-maintenance.com/maintenance_articles_failure.shtml (7 of 10) [5/12/2004 11:37:41 PM] Failure Analysis Articles

Root Cause Failure Analysis courtesy of Reliability Center, Inc. Root Cause Failure Analysis - Understanding Mechanical Failures Machines aren’t supposed to break, and mechanical components such as shafts, fasteners, and structures aren’t supposed to fail. But when they do fail, they can tell us exactly why. Root Cause Failure Analysis Saves Inland Steel $1.15 Million courtesy of Reliability Center, Inc. Root Cause Failure Analysis: Interpretation of Fatigue Failures By far, the majority of mechanical failures happen from fatigue. (If someone asks you why something failed, just tell them fatigue. You’ll be right 90% of the time and that’s a great average in any activity.) But saying that fatigue caused a failure is like saying the hill caused a car’s brakes to fail. The value of failure analysis is that you can use it to look at the broken parts, determine the type and magnitude of the forces involved, then do something to prevent their recurrence. Root Cause Failure Analysis: The Case of the Frequent Bearing Failures This is the third in a series of articles on Root Cause Failure Analysis that examines some of the available metallurgical and physical evidence. Root Cause Failure Analysis: Understanding Mechanical Failures Machines aren’t supposed to break, and mechanical components such as shafts, fasteners, and structures aren’t supposed to fail. But when they do fail, they can tell us exactly why. sci.engr FAQ on Failures -- part one Supporting Root Cause Analysis: A Manager's Perspective Tacoma Narrows Bridge Disaster The "Soft Side" of Root Cause Analysis courtesy of Reliability Center, Inc. The Essentials of Conducting a Successful Root Cause Failure Analysis courtesy of Reliability Center, Inc.

http://www.plant-maintenance.com/maintenance_articles_failure.shtml (8 of 10) [5/12/2004 11:37:41 PM] Failure Analysis Articles

The Failure Dilemma How do I move towards Proaction when I work in such a Reactive environment. Courtesy of Reliability Center, Inc. The Pontiac that was Allergic to Vanilla Ice Cream For the engineers among us who understand that the obvious is not always the solution, and that the facts, no matter how implausible, are still the facts.. The Power of Failure Analysis to Eliminate Process Interruptions courtesy of Reliability Center, Inc. The Problem with Problem Solving Why do so many problems still exist? The answer becomes readily apparent when we realize that the science of problem solving often takes a back seat to the other more pressing day-to-day issues we face during everyday operations The RCFA Paradox courtesy of Reliability Center, Inc. Understanding the Multiple Roots of Machinery Failures Looking at the newspapers we frequently see statistics on the cause of some group of failure events shown as a pie chart or other chart adding up to 100%. Also, we frequently hear television announcers citing the latest study where they say things like “X percent of all home accidents are caused by poor lighting” or “Y percent of deaths are caused by cigarette smoking”. The idea that an accident occurred or a piece of equipment broke down because of the error of a single person or a simple design error would be nice – but usually it doesn’t hold up to scrutiny in the real world. What Is Root Cause Failure Analysis? courtesy of Reliability Center, Inc. What is the difference between Failure Analysis (FA), Root Cause Analysis (RCA) and Root Cause Failure Analysis (RCFA)? What is the Ultimate Goal of Implementing RCA? No matter what Root Cause Analysis (RCA) process that your firm has decided upon, "What is considered a successful RCA effort?" Who Said That???!!! Why Asking "Why?" Doesn't Work

http://www.plant-maintenance.com/maintenance_articles_failure.shtml (9 of 10) [5/12/2004 11:37:41 PM] Failure Analysis Articles

Why Engine Thrust Bearings Fail Why Root Cause Analysis Doesn't Always Work When performing true RCA, getting to the causes is the easy part, getting something done to eliminate the causes is a whole different story. Courtesy of Reliability Center, Inc.

http://www.plant-maintenance.com/maintenance_articles_failure.shtml (10 of 10) [5/12/2004 11:37:41 PM] Miscellaneous Maintenance Technical Articles Plant Maintenance Resource Center

Miscellaneous Maintenance Technical Articles

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Miscellaneous Articles on Maintenance Technical Issues

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"Seeing is Believing" Stroboscope Techniques A Comparison of Ceramic and Plastic Components A Guide to Healthy Batteries Advantages of Vertical Configuration Unit Ventilators VCUV's are an option for a cost effective means to meet current ventilation requirements. An Intelligent Conveyor Control System For Coal Handling Plant Of Thermal Power Plant - requires free Adobe Acrobat Reader for viewing. Barringer & Associates - recent Technical Papers

Censored Data Dealing with censoring data in Reliability and Maintainability studies Chromate Removal In Closed HVAC Recirculating Systems Cleaning Ducts And Ventilation Systems A how to article with regard to cleaning your facility's duct systems.

http://www.plant-maintenance.com/maintenance_articles_misc_tech.shtml (1 of 10) [5/12/2004 11:37:43 PM] Miscellaneous Maintenance Technical Articles

Combining Data http://rac.alionscience.com/pdf/COMBINE.pdf An overview of combining reliability data. - requires free Adobe Acrobat Reader for viewing. Condition Monitoring for Diesel Engines Diesel engine analysis involves periodic, non-intrusive measurement and inspections that provide time-domain, frequency-domain, and process-related data to measure and evaluate mechanical condition, operating performance, and to improve or maintain economic performance. Considerations To Prevent Growth And Spread Of Legionella In HVAC Systems Discusses what steps need to be taken to prevent the growth of Legionella Pneumophila Corona & Testing - Who, What, When, Where & Why Covering the necessities of press maintenance Several pressmen have contacted me this last month wanting to know what the best method is for setting rollers. Many also had questions concerning premature wear of press equipment. This article discusses several of these topics and other topics that I have selected on press adjustments and maintenance. Did You Know? Selection of "did you know's" from Idcon Discoveries during Development of the next generation Ultrahigh Pressure Water Jetting Machines This article argues that surface preparation before repainting will be much more effective in the future with the adjusted ultrahigh pressure water jetting method. In the past, water jetting equipment has been far too large and of course several times too expensive. New generation water jetting equipment may well will oust sand blasting and similar techniques because of their problems with dust, sand disposal etc. EDM Design EDM is one of the most accurate manufacturing processes available for creating complex or simple shapes and geometries

http://www.plant-maintenance.com/maintenance_articles_misc_tech.shtml (2 of 10) [5/12/2004 11:37:43 PM] Miscellaneous Maintenance Technical Articles

Engine Balance - The Thinking Has Changed Balanced combustion on reciprocating engines is important for reliable, emission-compliant operation. Through the years, a number of engine balance techniques have been developed and utilized. Unfortunately, no clear-cut standard has been established for engine balance methodology or frequency. This paper will discuss the fundamentals of engine balance, describe the history of balancing, and present the most current thinking on proper engine balance technique, equipment, and frequency. Evaluating Alternative Refrigerants: A Guide To The Criteria For Refrigerant Selection The mandated phase-out of CFC refrigerants has brought many educational and health care facility managers face-to-face with a difficult question: Which new refrigerant is the best choice for the future? Failure of Dust Suppression Systems in Coal Handling Plants Generally all systems used in power station coal handling plants are wet dust suppression systems. In this paper the reasons for failure of these type of dust suppression system are discussed. The remedy for the improvement of this system is also given in this paper. - requires free Adobe Acrobat Reader for viewing. Gearbox Diagnostics Fault Detection The article discusses the method of gearbox diagnostics fault detection, and shows that using: design, production technology, operational, change of condition (DPTOCC) factors analysis leads to inference diagnostic information. Heeding the Screams of Sick Machines The human ear can’t pick up the wails but ultrasound can.

http://www.plant-maintenance.com/maintenance_articles_misc_tech.shtml (3 of 10) [5/12/2004 11:37:43 PM] Miscellaneous Maintenance Technical Articles

Hydraulic Lifters / Pushrods: are they worth it? The “hype” describes those features and benefits that are typically touted by sales persons to describe the basic theory, design, and manufacturing concept of hydraulic lifters and pushrods. The “facts” represent the field application and real-life experiences of operators using the equipment. This article, written by Charles G. Ely II, of Anderson Consulting, Training & Testing, and based on a survey of five oil and gas companies, compares the touted features against field experience - requires free Adobe Acrobat Reader for viewing. Indoor Air Quality Concerns Discusses Sick Building Syndrome and how facility managers can identify and correct IAQ problems. Inductive Ignitions Yield Reliable Firing Inductive ignition systems are gaining popularity over capacitive discharge systems because they can provide more reliable firing in lean burn engines due to the prolonged arc. Inspection and Maintenance Guidelines - Shackles Investing In Energy Efficiency: A Proven Strategy For Reducing Operating Costs The EPA's ENERGY STAR® Buildings and Green Lights® Programs provide organizations with an effective, profitable strategy to eliminate wasted energy from their facilities. Journal of Quality in Maintenance Engineering: Articles Keeping Threaded Fasteners in Their Place Keeping fasteners tight, particularly threaded fasteners, seems like a simple task, but the moving nature of the machinery they are used on is what makes them so troublesome Listening For The Leak The overalled fitter marching around the Ford Stamping Plant in Geelong, Victoria, with earphones on is not listening to the latest gig by the Red Hot Chili Peppers or the Hot House Flowers Locating Tube Leaks at Nylon Plant In recent years, Allied- Signal's Reliability Services group has searched out new techniques to extend or improve existing methods. Airborne ultrasonic scanning, which came to its attention last spring, is one of these new approaches.

http://www.plant-maintenance.com/maintenance_articles_misc_tech.shtml (4 of 10) [5/12/2004 11:37:43 PM] Miscellaneous Maintenance Technical Articles

Minimizing Refrigerant Emissions in HVAC Systems Actions a facility manager should take when implementing a leak management program. New Ultrasonics Systems Locate Leaks Beneath Pavement Ultrasonic detectors being sensitive to a specific range of ultrasound, between 20 and 100 kilohertz, sense the ultrasonic emissions produced by a leak. Often Overlooked, Sprinkler-System Training Can Save Lives This article describes the two most used sprinkler systems that are installed in plants: wet sprinkler and dry sprinkler fire- fighting systems. Performance Monitoring System For Electromagnetic Vibrating Feeders Of Coal Handling Plant In this paper a simple system, which easily monitor feeding rate to help operator to control plant, is discussed. Many times operator cannot judge performance of feeder. This system is very useful to judge the performance. A mathematical relation is shown in paper for feeding rate. - requires free Adobe Acrobat Reader for viewing. Persistence needed to track TV/radio Interference When a complaint is about TV interference or the inability to get a specific radio channel, a specialist must be assigned to the case. New York State Electric & Gas Corp (NYSEG) relies heavily on ultrasonic technology Pipe Corrosion And Its Growing Threat To Office Building and Plant Operations Plate And Frame Heat Exchangers --- The Ultimate Safeguard For Critical Or Problem Condenser Water Applications Practical tips for selecting the right casters It's simply about asking the right questions Preventing The Formation Of Scale In HVAC Humidification Pans Pruftechnik Direct On-Line Maintenance Catalogue Laser Alignment, Condition Monitoring, NDT and Technical Articles

http://www.plant-maintenance.com/maintenance_articles_misc_tech.shtml (5 of 10) [5/12/2004 11:37:43 PM] Miscellaneous Maintenance Technical Articles

Reducing The Microbiological Count Of Decorative Fountains Using Ultraviolet Water Purification Refrigerant 8-Ball Questions Testing Your Refrigerant Plan Establishing a good strategic refrigeration management plan requires that the execution of that plan remain dynamic. Reliability Engineering Snapshot - Corrosion Chloride stress corrosion cracking (CSCC) requires chloride and stress. To eliminate one is to eliminate the phenomena. In short, you can't have CSCC if one element is missing. Reliability Toolkit Reliability Engineer's Toolkit (Free PDF Download). The Reliability Engineer's Toolkit is a 274 page guide book covering topics ranging from tailoring a reliability program based on external constraints to providing useful information about reliability design, analysis and testing. It was developed by the USAF Rome Laboratory. - requires free Adobe Acrobat Reader for viewing. Research Overview 1998 - Institute of Mechanics, ETH Zürich Assorted research reports into NDT techniques Safely Removing Iron Oxide, Dirt, Organic Material, And Other Corrosion Products From Interior Pipe Surfaces Using High Pressure Water Jet Saving Energy Dollars With Ultrasonic Predictive Maintenance Compressed air is not a free utility. In fact, it may very well be the most costly utility a company uses. It is good business, as well as good management policy to carefully look at the use and efficiency of a compressed air system Survey of Plant Capacity Utilization From the US Census Bureau

http://www.plant-maintenance.com/maintenance_articles_misc_tech.shtml (6 of 10) [5/12/2004 11:37:43 PM] Miscellaneous Maintenance Technical Articles

Tea Staining on Stainless Steel Surfaces Tea staining of stainless steels is a relatively common occurrence in coastal areas, and wherever water which high in chlorides is used for washing down. Visually, it is a discolouration of the metal surface, which tends to follow the ‘grain’ of any surface finish. Although unpleasant to look at, it is not a serious form of corrosion, and in general does not affect the structural integrity, or longevity of the equipment. Aesthetically however tea staining is not ideal. This paper, from Barry Walker, Don Thornton & Simon Griffiths, is designed to help identify its causes and suggest remedies that have proven to be satisfactory in practice. Technology Overview: Ultrasonic Detection Some of the most common plant applications are: leak detection in pressure and vacuum systems (i.e., boilers, heat exchangers, condensers, chillers, distillation columns, vacuum furnaces, specialty gas systems), bearing inspection, steam trap inspection, valve blow-by, pump cavitation, detection of corona in switch gear, compressor valve analysis, and the integrity of seals and gaskets in tanks, pipe systems and large walk-in boxes. The amazing quick exhaust valve Cylinder speed control is just one of the many uses for this versatile component The Extreme Importance Of Proper Cleanout And Start-Up For Any HVAC, Fire Sprinkler, Or Process Water System The Money Leaking From The Mechanical Room: A Practical Guide To Addressing Chiller Leaks Explains the importance of leak prevention and specification of advanced chiller design. The Negative Impact Of Frequently Draining And Filling A Fire Protection System The Power of Vacuum Ever wondered how vacuum pressure really works? Here's a straightforward explanation for industrial applications The Problem of Uncertainty This article is part of the Reliability Handbook, originally published by PEM magazine in Canada. - requires free Adobe Acrobat Reader for viewing.

http://www.plant-maintenance.com/maintenance_articles_misc_tech.shtml (7 of 10) [5/12/2004 11:37:43 PM] Miscellaneous Maintenance Technical Articles

The R&M Case - A Reasoned, Auditable Argument Supporting the Contention that a System Satisfies its R&M Requirements One method of ensuring that product meets customers Reliability and Maintainability requirements - requires free Adobe Acrobat Reader for viewing. The Smart Machine Alan Friedman of DLI Engineering discusses the level of intelligence available from the latest tranche of computer-controlled maintenance devices, and muses on the parallels between machine-speak and human language (Courtesy of Coxmoor Publishing) - requires free Adobe Acrobat Reader for viewing. The True Threat Of A High Corrosion Problem To A Fire Sprinkler Line Tips for Blower Maintenance This article is intended to provide a few tips to plant maintenance professionals, in reducing the downtime and increasing the reliability, of blowers. Tube Coating With Teflon ® --- An Outstanding Alternative To Condenser And Chiller Tube Replacement Ultrasonic Detector Locates Boiler Casing Leaks Many undetected casing leaks plagued one of our large watertube power boilers, even after extensive work was done to repair it. Ultrasonic Detectors: Another Tool for the Power Quality Engineer Power quality and facility maintenance engineers should consider the use of ultrasonic detection equipment for evaluating equipment and facilities Ultrasonic Device Versatile Concerned with equipment failures and increasing downtime, management of Alcoa's Newburgh plant decided to upgrade their preventive maintenance efforts. Ultrasonic probe spots pressure, vacuum leaks, identifies bad bearings By sensing subtle ultrasonic changes in equipment, the Ultraprobe 2000 by UE Systems Inc., locates leakage in heat exchangers, pneumatic systems and steam traps.

http://www.plant-maintenance.com/maintenance_articles_misc_tech.shtml (8 of 10) [5/12/2004 11:37:43 PM] Miscellaneous Maintenance Technical Articles

Ultrasonic technology 'picks up' preventative maintenance Ultrasonic scanning instruments are fast becoming standard tools for preventative maintenance programs in the food processing industry Ultrasonic Tool Averts Costly Breakdowns Increasingly, facilities professionals are using ultrasonics technology in conjunction with other inspection tools. Ultrasonics Detects Leaks at Ford With so many "look alike" cars around in each price range, customer's loyalty depends on the faith in the quality of the car he or she has most recently bought. Air and water leaks, therefore, can be as disturbing to customers as mechanical defects. Understanding pneumatic power circuits Pneumatic directional control valves and cylinders are most commonly used in power circuits, with the valves controlling cylinders that, in turn, provide work. As we learn about a few of these circuits, other accessory valves will be introduced, along with some interesting ways of using them. Using air-over-oil circuits for more controllable pneumatic power The big advantage of a single-tank system is that the frictional losses are half that of the double-tank system Using mechanical methods to generate linear motion Mechanical rotary-to-linear motion conversion drives can move and position loads with varying degrees of precision, but must be guided in their lineal motion to be effective in practical automation applications. Water Treatment Gadgets - Historical Failures Of Corrosion Control Weighing the Options of Chiller Maintenance In order to get approval for a project, it is sometimes necessary for a contractor to review, explain, estimate and present all of the various avenues an owner can take with their CFC chillers. - requires free Adobe Acrobat Reader for viewing. What exactly is a decibel? You've probably heard the term "decibel" over the years. But what exactly is a decibel? This article should clear up some of the confusion.

http://www.plant-maintenance.com/maintenance_articles_misc_tech.shtml (9 of 10) [5/12/2004 11:37:43 PM] Miscellaneous Maintenance Technical Articles

Why An Open Condenser Water System Is Provided Less Chemical Protection Than A Closed Piping System

http://www.plant-maintenance.com/maintenance_articles_misc_tech.shtml (10 of 10) [5/12/2004 11:37:43 PM] NDT Articles Plant Maintenance Resource Center

NDT Articles

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Articles on Non-destructive Testing techniques (NDT)

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A New ASTM Standard for Remote Field Testing (RFT) Eddy Current inspection - the theory How Ultrasound Works Human error as a factor of corrosion failures When all the human errors and management system deficiencies are included, the typical machine breakdown is the result of somewhere between five and ten significant contributors Inspection and Welding Repairs of Pressure Vessels This paper aims to provide an overview of welding inspection and repairs of pressure vessels that can be conducted in Shut downs within Chemical, Refinery, Petrochemicals and Fertilizer industries. It discusses various methods of weld repairs and related activities such as testing after welding - requires free Adobe Acrobat Reader for viewing. NDT: An Introduction Covers all of the basic NDT techniques Quality Magazine Nondestructive Testing Articles The Benefits Of Ultrasonic Testing In Determining Pipe Corrosion Rate, Pitting, And Remaining Service Life

http://www.plant-maintenance.com/maintenance_articles_ndt.shtml (1 of 2) [5/12/2004 11:37:44 PM] NDT Articles

The Growing Importance of Nondestructive Testing For A Successful Building Or Plant Operation

http://www.plant-maintenance.com/maintenance_articles_ndt.shtml (2 of 2) [5/12/2004 11:37:44 PM] Technical Articles - Painting, Protective Coatings and Roofing Maintenance Plant Maintenance Resource Center Technical Articles - Painting, Protective Coatings and Roofing Maintenance

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Articles on Protective Coatings, Painting and Roofing

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How To Respond To Roof Leaks Methods for handling roof leaks and how to get manufacturers and/or contractors to fix leaks. Roofing Maintenance Detailed recommendations on how to begin and continue to conduct roof inspections. Time To Check Your Roof Provides suggestions on who facility managers should put in charge of conducting roof inspections.

http://www.plant-maintenance.com/maintenance_articles_painting.shtml [5/12/2004 11:37:44 PM] Technical Articles - Power Transmission, Gearbox and Vee Belt Maintenance Plant Maintenance Resource Center Technical Articles - Power Transmission, Gearbox and Vee Belt Maintenance

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Articles on Maintenance of Power Transmission Systems, Gearboxes and Vee Belts

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Avoiding Power Transmission Equipment Maintenance Errors Here are some tips to prevent often-seen installation and maintenance mistakes that lead to recurring downtime Gearing Up for Hot Temperature - Thermal Limits of Gearboxes Heat Resistance in Power Transmission Belts Proper Coupling Selection Proper Installation and Maintenance Can Prolong the Life of V- Belts Spider insider Understanding spiders and the role they play in the performance and maintenance of jaw couplings is important, because selecting the right type of spider is just as significant as selecting the right type and size of flexible jaw coupling Switching Gears Can Cut Your Energy Costs Vee Belt Drives Basic theory of friction drives and lists 11 factors to be considered in order to ensure reliable operation of vee-belt drives. - requires free Adobe Acrobat Reader for viewing.

http://www.plant-maintenance.com/maintenance_articles_pt.shtml (1 of 2) [5/12/2004 11:37:45 PM] Technical Articles - Power Transmission, Gearbox and Vee Belt Maintenance

http://www.plant-maintenance.com/maintenance_articles_pt.shtml (2 of 2) [5/12/2004 11:37:45 PM] Technical Articles - Pumps and Seals Plant Maintenance Resource Center

Technical Articles - Pumps and Seals

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Articles on Pumps and Seals

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A little bit more about Cavitation Just what then is this thing called cavitation? A little bit more about troubleshooting centrifugal pumps and mechanical seals One of the U. S. based Japanese automobile manufacturers has a unique method of troubleshooting any type of mechanical failure. The system is called the "Five Whys". A maintainer's guide to Treating Centrifugal Pumps Tips for safely repairing, lubricating and aligning pumps. A new way of classifying chemicals to assure effective sealing The most common question asked by seal salesmen is "what are you sealing?" A technique for making pump troubleshooting decisions The rules are very simple. Decisions have to be made when doing nothing will cause the condition to degenerate. A.P.I. (American Petroleum Institute) and C.P.I. (Chemical Process Industry) merger Any prediction about the future of the pump and seal business would have to include the high probability that the CPI will adopt the API seal standard Affinity laws for positive displacement pumps The affinity laws accurately predict the affect of changing the speed of a positive displacement pump

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (1 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Affinity laws- what happens when you change the pump speed or impeller diameter? There are occasions when you might want to permanently change the amount of fluid you are pumping, or change the discharge head of a centrifugal pump. There are four ways you could do this Alignment between the pump and driver In the pump business alignment means that the centerline of the pump is aligned with the centerline of the driver. Although this alignment was always a consideration with packed pumps, it is critical with sealed pumps especially if you are using rotating seal designs where the springs or bellows rotates with the shaft All about impellers Simply - all about impellers! All about NPSH 15 Simply - all about Net Positive Suction Head (NPSH)! ANSI pump Standard ANSI is an acronym used to describe the American National Institute Pump Standard. The standard evolved from the American Voluntary Standard (AVS) that was first proposed by the Manufacturing Chemists Association in the nineteen fifties. It is a set of inch dimensional standards that describe the envelope dimensions of a back pull out, centrifugal pump API Gland The seal gland is that part that holds the stationary half of the mechanical seal and attaches to the stuffing box. The most universally used gland is labeled the American Petroleum Institute (API) gland API plans that I use The American Petroleum Institute (API) issues guide lines to help petroleum people select and then pipe various types of controls for mechanical sealing applications. These piping arrangements are described in a series of plans issued by the API. Ball bearing lubrication in centrifugal pumps It turns out that bearings fail for two main reasons: Contamination of the bearing oil by water or moisture or High heat often caused by too much lubrication Barrier or buffer fluid. The liquid we circulate between dual seals. Let's clear up the confusion about flushing seals Bearing fit tolerances Bearing Fit tolerance charts

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (2 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Calculating net positive suction head (NPSH) in non-metric units To calculate the net positive suction head (NPSH) of your pump and determine if you are going to have a cavitation problem, you will need access to several pieces of information Calculating the centrifugal pump first critical speed The first critical speed is linked to the pump's static deflection. Carbon graphite seal faces - how they are manufactured and where carbon/graphite cannot be used Seal companies purchase carbon/ graphite molded faces from one of several carbon manufacturers. The seal companies pay for the necessary molds and then retain the exclusive use of them Carbon seal faces; which is best? Solid or pressed in a metal holder? Carbon Graphite is probably the best seal face you can use in most of your water and chemical applications Causes of overheating in cartridge seal designs Too much heat can cause multiple problems with mechanical seals Cavitation Cavitation means that cavities are forming in the liquid that we are pumping. The cavities form for five basic reasons. Centrifugal pump ball bearing seals Bearings are normally lubricated with either oil or grease. Oil mist is another alternative, but recent fugitive emission regulations are making this form of bearing lubrication less desirable Centrifugal pump formulas, rules and definitions Some of the basics you need to understand centrifugal pumps Centrifugal pump shaft displacement We know that seals fail for only two reasons: One of the seal components becomes damaged, or the lapped faces open Centrifugal pumps - what is wrong with their design Ask for a pump recommendation from your favorite supplier and chances are he will recommend one of the standard pump designs that conform to either the A.N.S.I., I.S.O. or D.I.N. specifications. On the surface that might seem like a good recommendation, but the fact is that all of these designs will cause you maintenance problems

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (3 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Changing the diameter of the piping to save operating costs Business has not been that good and production has decided that maybe they can save costs if they increase the piping size so that a smaller and more economical motor can be used and the possibility of cavitation can be reduced. What exactly is going to happen to the horsepower requirement for this new installation? Will the additional cost of converting to larger piping be justified by the lower operating costs? Classifying seals by the operating conditions It is extremely important for any modern process company to have a good set of seal specifications Concentric dual seals Dual seals are recommended for a variety of purposes Condensate - why you must seal it We want to keep dissolved oxygen out of condensate. Why? Controlling temperature in the pump stuffing box Many fluids are adversely affected by a change in their temperature, and when this reaction takes place seal failure is almost sure to follow Converting head to pressure the definition of some pumping terms Corrosion problems associated with stainless steel The rotating equipment business uses a great deal of 300 series stainless steel, and as a result we often experience corrosion that is described in a variety of technical terms Dangerous fluids, how to seal them The definition of fluids includes both liquids and gases and any of these fluids could be labeled dangerous for a variety of reasons Density and specific gravity We often describe a fluid by its "lightness or heaviness". Design, operation, and maintenance problems associated with mechanical seals The purpose of this paper is to give you an overview of the subject, and assist you in your troubleshooting function

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (4 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Diaphragm Pump Troubleshooting While air-operated double diaphragm pumps have become popular in the process industry for their inherent ability to meet changing application demands, the affects of cavitation should be understood and the resulting loss of capacity and decrease in diaphragm flex life addressed Double volute pump the advantages of using a double volute centrifugal pump to eliminate radial shaft deflection caused by operating off the best efficiency point (BEP) of a single stage centrifugal pump Dynamically balancing the pump rotating components Everyone agrees that balancing the rotating components of a centrifugal pump is a good idea, but it is seldom done. Elastomers - selecting the correct O-ring for the application The guide is an attempt to select the fewest number of elastomers that will give you satisfactory sealing of most of the chemicals we find in the process industry Elastomers - where the special compounds do not work In recent years the elastomer industry has produced a variety of newer compounds that appear to be getting closer to the universal rubber that we are all seeking. Unfortunately we are not there yet, so this paper is an attempt to put these "super compounds" into a proper perspective Environmental controls - controlling pressure in the stuffing box We have very little control over the products that we must seal, but we have a great deal of control over how we elect to seal them Environmental controls and special seals For any given seal application problem there are two generally accepted solutions Estimating the shutoff head of a centrifugal pump In the fifteenth century the Swiss scientist Daniel Bernoulli learned that the combination of head and velocity was a constant throughout a piping system. He then wrote the formula showing the relationship between this liquid velocity, and resultant head Flow through a Venturi Here is the formula for an approximate flow through a venturi tube Flow through an orifice The equation for flow through an orifice is a simple one to understand. Only the units are somewhat awkward

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (5 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Flow. How the resistance is affected by any change of flow in a pipe What happens when we change the flow going through a piping system? Fugitive emissions - the chemicals on the list In this paper I have noted the chemicals that are presently on both the Carcinogen and Fugitive Emissions lists. The compounds on these lists should be sealed with two (dual) mechanical seals to prevent their escaping to the atmosphere and violating the applicable restrictions or possible harming personnel in the area Grout for the pump base The forces and vibrations present in our rotating equipment must be absorbed by the foundation or they will be transmitted to the mechanical seal and pump bearings, causing higher stresses and premature failure of one or both of these components Head - calculating the total head in inch units To calculate head accurately we must calculate the total head on both the suction and discharge sides of the pump. In addition to the static head we will learn that there is a head caused by resistance in the piping, fittings and valves called friction head, and a head caused by any pressure that might be acting on the liquid in the tanks including atmospheric pressure, called " surface pressure head". Head - calculating the total system head in metric units To calculate head accurately we must calculate the total head on both the suction and discharge sides of the pump. In addition to the static head we will learn that there is a second head caused by resistance in the piping, fittings and valves called friction head and a third head caused by any pressure that might be acting on the liquid in the suction or discharge tanks including atmospheric pressure. This third head is called " surface pressure head". Head - changes in the discharge head We have to know the discharge head of a centrifugal pump for several reasons. We can have many problems determining accurate head information because of variations in the discharge system Head, Pressure and Mr. Bernoulli The term "pressure" can be a little confusing because the units we use to measure pressure change in various parts of the world

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (6 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Heat, how it affects the pump and mechanical seal Every day salesmen call on customers and make claims that their pump or mechanical seal can take more heat than the other guys. Before we rush out to purchase these wonder products we should take a closer look at the heat problem How pipe friction, liquid capacity and pump head are affected by the amount of liquid flowing through a pipe You can use the following formulas to supplement the Affinity Laws How the shape of the pump impeller affect the pump curve In this paper we are going to see how the shape of the pump impeller affects both the slope of the pump curve and the amount of horsepower that will be consumed by the pump at various capacities How to tackle corrosion in submersible pumps Materials, techniques and tips to control pump deterioration caused by environmental and corrosive liquid conditions. Hydrodynamic gas seals The idea is very simple. Let the seal faces ride on a film of gas either pumped to or flowing between the seal faces. Unlike hydrostatic seals that create a balanced opening and closing force to maintain just the right amount of seal face separation, the hydrodynamic seal depends upon the generation of a lifting force to separate the seal faces Hydrostatic sealing This paper is all about hydrostatic sealing and the principle behind this type of seal is not too difficult to understand Increasing the centrifugal pump performance by modifying the impeller What happens when you reduce the impeller vane diameter? Installing pump piping A few things you should know about your pump's piping system Installing pumps A reminder of a few things you should know about installing pumps It's all in the connections Here is a step-by-step guide, from mounting to connecting piping and couplings to shaft alignment, that will make your next pump installation easy.

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (7 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Maintenance practices that cause seal & bearing problems Here are some of the maintenance practices that increase pump failure rate Mechanical Seal hydraulic balance Seal hydraulic balance is one of the most effective tools we have to counter the detrimental affects of heat being generated in the stuffing box area. The original patent for hydraulic balance was granted in 1938, but the concept has never been adopted by the "original equipment manufacturer" (O.E.M.), and so to this day it remains only as an "after market" product. Mechanical Seal Principles & Operation An introduction to basic rotary mechanical seals as their applied to centrifugal pumps and positive displacement pumps Metal bellows seals An overview of metal bellows sealing Monitoring the centrifugal pump A sensible predictive maintenance program for centrifugal pumps is still an elusive dream for most plants More about packing conversion Sales people constantly preach the virtues of converting that nasty, greasy packing to a brand new, shiny, expensive mechanical seal. Their presentation makes a lot of sense and besides that the government is passing new legislation that is making conventional packing more obsolete by the minute. If you are about to make one of these conversion in your plant there are some things that you should know to make the transition easier Non metallic seals A portion of the chemical industry use non metallic pumps. You will find them manufactured from Teflon®, graphite, Carbamate, and a variety of other materials. Common sense dictates that if the application engineer selected a non metallic pump, he must of had a good reason for doing so, and it would not be logical for you to equip it with a mechanical seal containing metal components exposed to the product unless you had specific knowledge that doing so would make some kind of sense.

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (8 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

NPSH required, allowable reductions The curve that came with your pump shows the NPSH required for any given impeller size and capacity. This number was determined by pumping cold water through the pump while reducing the suction head until the pump showed a reduction in discharge head of three percent (3%), due to the low suction head and any formation of bubbles within the pump. This point is called "the point of incipient cavitation. Open vs.Closed impeller design pumps There are advantages and disadvantages to each design Operating practices that cause maintenance problems There are three types of problems we encounter with centrifugal pumps and poor operation is one of them. Oversized pumps Do a survey of any process plant and you will find that a high percentage of the centrifugal pumps are oversized. There must be a reason why this is such a common problem Packing conversion - why you should do it and the possible savings Packing conversion is a subject that has become more important in recent years. The savings that are real and easily measurable Parallel piping for pumps There are some considerations you must address when using parallel pumps Positive displacement pump troubleshooting A troubleshooting guide for positive displacement pumps Positive displacement pumps Rotary pumps make up about 10% of the pumps we use in industry. Unlike the more common centrifugal design they are PD (positive displacement) pumps Predictive maintenance for centrifugal pumps Is there a reliable method of introducing a centrifugal pump predictive maintenance program? Preventative maintenance - pumps A sensible preventative maintenance program for centrifugal pumps cheat sheet Preventative maintenance - pumps and seals Pump and seal preventative maintenance - what is it all about? Preventative maintenance - seals A sensible preventative maintenance program for mechanical seals, cheat sheet

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (9 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Priming the centrifugal pump Why you must prime a centrifugal pump Pulsation Dampening & Surge Suppression The control of fluid dynamics is essential to ensure efficient and safe use of process systems. Uncontrolled fluid in motion can physically destroy a pumping system, including the pump, piping, valves, meters, back pressure valves, rupture disks and other in-line instrumentation and equipment Pump & Process System Protection Understanding positive displacement pump operation and the risk of pump and system over pressurization is critical to process integrity, operator safety and successful pump and process component life Pump and seal problems with no apparent cause These problems are the ones that drive you crazy. No matter how hard you look the solution keeps evading you. Over the years I have collected quite a few examples. I offer some of them for your enjoyment and maybe, in the process, they will help you solve the "un-solvable" Pump bearings, why do they fail? Most of us change the bearings every time we disassemble the equipment to replace the mechanical seal or the packing sleeve. Is this really a sensible thing to do? Pump charts and graphs you will need Pump curve - how to read one How to read a pump curve Pump efficiency - figuring the heads How efficient is your pump? Pump efficiency - making the calculations What do we mean by pump efficiency? Pump modifications to increase seal life Pump modifications you can make to increase the life of mechanical seals and centrifugal pump bearings Pump Partnering With all the current talk about seal partnering, can pump partnering be far behind? As with mechanical seals the concept is simple; call in several pump companies, talk to them about a lot of lofty ideals and then learn which of them will give you the best price on a standard ANSI (American National Standards Institute) pump if you promise to give them all of your business.

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (10 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Pump Performance Checklist Pump rebuilding tips Some pump rebuilding tips to prevent future vibration problems Pump reliability Have you joined the bandwagon? Are you purchasing to a company or engineering standard of some type and made the capital investment in the reading and recording data? Pump selection practices that cause maintenance problems Purchasing well designed hardware does not bring automatic trouble free performance with it. The very best equipment will cause problems if it was not designed for your particular application Pump-related conversion tables Velocity, Mass Flow rate, Force, Pressure and Liquid Head, and more Pumps - additional information you need Some more things you should know about centrifugal pumps Pumps installed in pits. How to correct some existing suction problems Pump-Zone.com Many articles about anything related to pumps Radial thrust calculations for centrifugal pumps Pump shaft radial thrust alternative calculations (in Imperial dimensions) Reading seal face flatness There is often confusion between the terms "Seal face flatness" and "Seal face surface finish". Repair of mechanical seals The days of sending mechanical seals back to the manufacturer, or having a local repair facility repair your seals will shortly come to an end Rubber bellows seal Available from a number of seal companies (the Crane #1 is typical), and manufactured in a variety of materials Rules of thumb - pumps If you want to know a pumps capabilities the rules are simple, look at the manufacturer's published pump curve. The problem is that you do not always have the curve available. Pump companies test their pump to determine its performance, they have no need for general guide lines or "rules of thumb."

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (11 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Rules of thumb - seals The following is offered as a guide when dealing with mechanical seals in general Rules of thumb -seals and pumps The biggest advantage of experience is you have hopefully learned what can get you into trouble. The following information has been explained in detail in previous technical papers, but I still see the same problems re- occurring on a daily basis Seal Application. Do you have one? You have three opportunities to do a mechanical seal application Seal design - the questions you should ask How do you test a mechanical seal? No two pumps are exactly alike; what is a fair test? Too often we test only how the seal performs when all the operating conditions are known and the seal is installed correctly. Seal face hardness testing The common methods seal people use to measure the hardness of a seal face Seal face lubrication What is really happening between the mechanical seal faces? Seal failure - some things you can do to prevent it Preventing premature seal failure Seal features - the ten most important The ten most important features you can specify in a mechanical seal design Seal hydraulic balance - two way balance for dual seals There are several reasons why you might want to invest in the higher cost of installing two seals in your pump, or some other pieced of rotating equipment Seal improvements in recent years Where have we been, and where should we be going? Seal installation Common seal installation mistakes that cause premature mechanical seal failure Seal life - how to get good seal life How to get good mechanical seal life Seal metal parts - selecting the right ones Selecting the correct metal for the mechanical seal components Seal misconceptions Some common misconceptions about mechanical seals

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (12 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Seal partnering The latest fad to hit the process industry is "partnering" allowing industrial academics to have a wonderful time thinking up these new projects so that they will appear to be doing something productive and useful. Although "partnering" implies many lofty benefits it always ends up being nothing more than purchasing negotiating a large discount from the seal manufacturer. The really important stuff that is costing you the most money, always takes second place. Seal value - how to get good value Getting what you pay for Sealing Energy Savings Sealing products sensitive to a change in temperature or pressure In this paper we will be considering how small changes in either temperature or pressure will cause failures to occur, and learn how to prevent these changes especially when the pump is stopped and often subject to both temperature and pressure fluctuations Sealing products sensitive to agitation This category of sealing is the one that is the least understood by most of the people that are involved in the process industry. Seals - as supplied by the original equipment manufacturer- the problems The next time you purchase a pump, mixer or some other type of rotating equipment and request that it be supplied with mechanical seals you are going to be very disappointed in the performance of those seals unless you specify exactly which brand, model and materials you want. Seals - preventing premature failure What is the best way to prevent a premature seal failure? Find out what is causing the failure and then take the necessary steps to prevent it. Seals - the most asked questions he most asked questions about mechanical seals Seals classification The classification of mechanical seals Seals. Which one should you buy? You're going to have to figure that one out yourself, but I can tell you which designs not to buy Selecting the correct hard face seal material A good mechanical seal should run leak free until the carbon/graphite seal face wears away

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (13 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Selecting the correct horsepower motor Electric motors operate at their best power factor and efficiency when fully loaded so you do not want to purchase a motor that is too big, and common sense dictates that one that is too small is even worse. In the following paragraphs we are going to learn how to select the correct motor for your centrifugal pump application Selection And Procurement Of Pumps For Replacement Reviews the various situations in which it may be better to replace, rather than repair, a pump Self priming pumps The concept is simple. Change the pump design so that the pump will retain enough fluid when it stops, to start again without having to worry about re-priming Shaft deflection Solving a major cause of shaft deflection in volute type pumps Shaft deflection Shaft deflection is certainly undesirable Shaft deflection - some calculations in inch and metric Shaft deflection and the pump best efficiency point Shaft deflection - three rules The three magic formulas you need to know if you want to understand how centrifugal pumps function Shaft deflection direction when operating off the BEP Some additional information about shaft deflection Shaft displacement and original equipment seals (O.E.M.) Shaft displacement and the original equipment seal (O.E.M.) Shaft fretting. What causes the problem? The next time you remove a grease or lip seal (the rubber seal located next to the bearing) you will note that the shaft is grooved and damaged under the rubber lip. You will see this same damage in a few other locations also Siphon, How it works Now just what is a siphon? Specific gravity It is important that you do not confuse specific gravity with viscosity Specific speed - how to calculate it Specific speed is a term used to describe the geometry (shape) of a pump impeller. People responsible for the selection of the proper pump, for their application, can use this Specific Speed information

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (14 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Specific speed vs. suction specific speed The difference between specific speed and suction specific speed Split mechanical seals The split seal is the one seal that every consumer wanted. The main reason that people continue to use packing is that no one wanted to take the pump apart just to fix a leak Standby pumps. Should they be run? If there were a simple answer to this question, it would never come up. The more I look into the subject, the more I'm convinced that there is no easy answer Stationary vs. Rotary seals One of the most difficult concepts to teach in writing is the difference in operation between stationary and rotating mechanical seals. It is like trying to write a set of instructions as to how to tie your shoe laces, easy to demonstrate, but difficult to explain Stuffing box Next to stabilizing the pump shaft, without question the single most effective action you can take to increase the life of your mechanical seal, is to replace the present narrow stuffing box with one of the newer more open designs Suction throttling Throttling the discharge of a centrifugal pump is a common method of stopping a cavitation problem System curve for positive displacement pumps Every pump manufacturer would like to recommend the perfect pump for your application. To do this he would like you to provide him with an accurate system curve that would describe the capacity and head needed for your various operating conditions Technical term correlations If you are going to be messing around with pumps, bearings and mechanical seals, these words are going to have to become a regular part of your vocabulary Temperature - causes of a rise in stuffing box heat Many factors contribute to a change in the pump stuffing box temperature Testing for Net Positive Suction Head Available (NPSHA) Centrifugal pumps are designed to pump liquids, not air. We are interested in the amount of NPSH available at the pump's suction flange because we want to insure there is enough head (pressure) available to prevent the fluid from vaporizing and causing gas bubbles.

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (15 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Testing for Net Positive Suction Head Required (NPSHR) How can you tell the NPSH required for your pump? It's easy, just ask the manufacturer! As logical as that sounds, we still find people assuming that if the know the NPSHR for pump brand "A" and pump brand "B" is the same size, both pumps should have the same requirement. So why isn't it true? The centrifugal pump is drawing too much amperage This is the third paper in a four part series about pump troubleshooting The centrifugal pump is not producing enough capacity This is the second paper in a four part series about pump troubleshooting The centrifugal pump is not producing enough head This is the first paper in a four part series about pump troubleshooting The centrifugal pump looses suction, the pump is cavitating This is the fourth paper in a four part series about pump troubleshooting The Critical Mistake Of Assuming That Clean Water Circulation Means A Clean Piping System The non seal pump Non-leak pumps have been the dream of pump designers ever since the first pump was invented back in the dark ages The problem with pump standards A Quick check of existing pump standards will reveal that there are a variety of them The reasons for premature bearing failure Bearings have no wearable surfaces, they are instead designed to fatigue after many hours of service The relationship between the pump L3/D4 and premature seal failure Some pump and mechanical seal sales people talk about L3/D4 . How important is the number when it comes to selecting a pump? The sealing of high pressure and hard vacuum High pressure does three things that will damage any mechanical seal The sealing of hot oil The largest user of hot oil pumps is the heat transfer oil customer. Many consumers use these products with oil temperatures exceeding 500° Fahrenheit (260° C.) and 600° to 700° F. ( 315° to 370° C.) becoming common

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (16 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

The sealing of hot water Water is normally considered a good lubricant and can do an adequate job of providing lubrication between the lapped faces of a mechanical seal, but there are a few problems The sealing of liquid slurries Whenever you deal with slurries there are several problems you must consider The sealing of mixers and agitators Tips for better sealing of mixers and agitators The sealing of non lubricants When we are discussing mechanical seals, a lubricant is defined as a fluid that has a film thickness of at least one micron (0.000039 inches) at its operating temperature and load. If the product we are sealing is not a lubricant we are forced to use the self lubricating characteristics of the carbon/ graphite mixture used in the manufacture of the seal face. The ten most important features you can specify in a single stage centrifugal pump design Here they are in no particular order Training for pumps and seals I often get e-mail inquiries asking about how to set up a pump and seal training program within a company. The inquiry almost always refers to a "hands on program" implying that this should be the program of choice. Is there a way to set up such a program? Troubleshooting common centrifugal pump problems You have four opportunities to trouble shoot centrifugal pumps and each opportunity can offer you a clue as to what is wrong with the pump Troubleshooting mechanical seal failure, a quick reference guide Of all the seal related activities, analyzing mechanical seal failure continues to be the single greatest problem for both the consumer and the seal company representative Troubleshooting mechanical seals at equipment disassembly After the failure has occurred you will frequently get a chance to analyze the failed components. You are going to be looking for several things. Troubleshooting mechanical seals at the pump site Leakage can occur at any time throughout the life of the mechanical seal. To troubleshoot seals effectively it is helpful to know just when the leakage starts. This is the advantage of being able to troubleshoot a running pump or one that is still hooked up to its piping http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (17 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Troubleshooting mechanical seals, an overview of the subject Seal problems are almost always associated with face leakage, but as we will soon learn there are other leak paths in addition to the obvious one between the lapped seal faces Troubleshooting rub marks in a centrifugal pump When a centrifugal pump is disassembled there are a couple of things visible to the trained trouble shooter. He can see either corrosion or evidence of rubbing, damage or wear. Using a variable speed motor to control flow in a centrifugal pump If you operate too far off the pump's BEP(best efficiency point) the shaft will deflect radially and that could lead to both seal and bearing problems. So what should you do if you have to vary the capacity of a centrifugal pump? Using Pump terms In any discussion of centrifugal pumps you will find that there are several terms that are interrelated Vacuum pumps The idea is simple enough. The pump will be designed to pump liquid as well as gas or vapors. If you need to create a vacuum you can connect your piping to the suction side of the pump, but if you need a positive pressure you can connect the piping to the discharge side of the same pump. Venting horizontal pumps Heat is always a problem with mechanical seals and any heat generated in the stuffing box is never desirable. When we fill the pump with liquid, air frequently becomes trapped in the stuffing box with no logical way for it to vent Venting vertical pumps Vertical pump applications are very different than horizontal pump applications because the stuffing box is often the high liquid point in the system. Air becomes trapped in the stuffing box and cannot get out. Vibration in a centrifugal pump - causes and cures It is necessary to be interested in vibration because it has a major affect on the performance of your pump Viscosity A primer on viscosity Viscosity corrections for Centrifugal Pumps Viscosity corrections to the pump curve

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (18 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Pumps and Seals

Water horsepower - how to make the calculation How to the calculate the water horsepower coming out of the pump What is the best pump and seal technology? The "Best Technology" phrase comes up in recent government regulations and every day plant conversations. So what is the best Mechanical Seal and Pump Technology available today? Why do not good seals wear out? We know that a mechanical seal is supposed to run until the carbon wears down, but our experience shows us this never happens with the original equipment seal that came installed in the pump. We buy an expensive new mechanical seal and that one doesn't wear out either. What is wrong? Was the new seal a waste of money? Why Seals Fail

http://www.plant-maintenance.com/maintenance_articles_pumps.shtml (19 of 19) [5/12/2004 11:37:48 PM] Technical Articles - Roller Chain Drive Maintenance Plant Maintenance Resource Center Technical Articles - Roller Chain Drive Maintenance

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Roller Chain Drives - Installation Roller Chain Drives - Lubrication Roller Chain Drives - Maintenance Roller Chain Drives - Troubleshooting

http://www.plant-maintenance.com/maintenance_articles_chain.shtml [5/12/2004 11:37:49 PM] Steam Trap Articles Plant Maintenance Resource Center

Steam Trap Articles

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How to Start a Steam System Maintenance Program Starting a Steam System Maintenance Program might seem like a large undertaking for many facilities; however, the benefits far outweigh any costs and effort involved. Implementing a steam system maintenance program can save time, reduce costs, and improve operating efficiency and product. - requires free Adobe Acrobat Reader for viewing. Inspect Steam Traps for Efficient System Faulty or inoperative steam traps can cause losses of hundreds of thousands of dollars. Maintaining Steam Traps Failed steam traps waste and adversely affect product quality. Therefore, a maintenance program for steam traps is a good investment Maintaining Steam Traps How to set up a maintenance program for steam traps that can pay for itself in less than a year. Steam Loss Chart Steam Solutions Steam Trap Management Software - providing the basis for "fact- based" decision making This article, contributed by Bruce Gorelick, V.P. of Marketing for Conserv-it Software outlines the key considerations in establishing a consistent, regularly scheduled trap maintenance program. http://www.plant-maintenance.com/maintenance_articles_steam.shtml (1 of 2) [5/12/2004 11:37:49 PM] Steam Trap Articles

Ultrasonic Testing Tips for Steam Traps & Valves Testing tips for common problem areas Ultrasonic Testing Tips for Steam Traps & Valves Ultrasonic Testing Tips for Steam Traps and Valves Testing tips for common problem areas Why is it so important for facilities to have a dedicated steam trap survey and repair program?

http://www.plant-maintenance.com/maintenance_articles_steam.shtml (2 of 2) [5/12/2004 11:37:49 PM] Thermography Articles Plant Maintenance Resource Center

Thermography Articles

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Articles on Thermography

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After the Switchgear Condition Monitoring in the 21st Century This article outlines some of the key business opportunities and issues which are driving change in the industry, summarises some of the resulting trends, and then draws some conclusions regarding the implications of these trends for Condition Monitoring equipment manufacturers and suppliers, Condition Monitoring contractors, and organisations employing Condition Monitoring techniques Fundamentals of Roof Inspections How & Why an IR Contractor Should Promote the Use of a Spot Radiometer for Client's In-House P/PM Programs. Infrared Building Inspections Infrared Inspection of Motors Locating Blockages in Boiler Tubes NFPA 70E NFPA 70E: More on Flash Protections Preventing Electrical Fires, Building Shutdowns, and Equipment Damage Using Infrared Thermography Repair Prioritization Based on Real Factors

http://www.plant-maintenance.com/maintenance_articles_thermography.shtml (1 of 2) [5/12/2004 11:37:50 PM] Thermography Articles

Specifications for Qualitative Infrared Thermographic Surveying of Electrical Switchgear The Case for Aerial Infrared Informative and educational treatise on the efficiency and cost effectiveness of the aerial infrared process The Difference Between On-Roof and Aerial Infrared Thermography The Steps to Professional Certification Thermal Analysis for Today's Complex Designs Thermal Imaging: It's More Than Just Pretty Pictures Thermal Imaging: More Critical Than Ever Understanding Aerial Infrared Roof Imagery Using Infrared Successfully An infrared (IR) device is like a camera, in that it has a limited field of view Why Record? (Infrared Video) Why should you be interested in thermal imaging? This technology allows you to quickly and comprehensively measure and map the heat and temperature of components and assemblies at the prototype stage not in the field

http://www.plant-maintenance.com/maintenance_articles_thermography.shtml (2 of 2) [5/12/2004 11:37:50 PM] Tribology and Oil Analysis Articles Plant Maintenance Resource Center

Tribology and Oil Analysis Articles

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Articles on Tribology and Oil Analysis

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Application of Dempster-Shafer Theory to Oil Monitoring In order to solve the problem of diagnosing wear in tribosystem, evidence theory of Dampster-shafer is applied to realize the information fusion of multi-parameter in oil monitoring Ball bearing lubrication in centrifugal pumps It turns out that bearings fail for two main reasons: Contamination of the bearing oil by water or moisture or High heat often caused by too much lubrication Bearing Failures Dry Up at Weyerhaeuser Case Study: Effective Fluid Management Delivers Big Time at the Port of Tacoma Case Study: Putting Onsite Oil Analysis to Work at Southern California Edison Charting the Roadmap to Success Clean Oil Sampling: How to Sample Oil Without Opening the Bottle Clean up your oil and keep it clean! Contaminated oil kills machines. Clean oil is one of the most important factors affecting the service life of the lubricated components of all machinery

http://www.plant-maintenance.com/maintenance_articles_tribology.shtml (1 of 5) [5/12/2004 11:37:51 PM] Tribology and Oil Analysis Articles

Condition Monitoring in the 21st Century This article outlines some of the key business opportunities and issues which are driving change in the industry, summarises some of the resulting trends, and then draws some conclusions regarding the implications of these trends for Condition Monitoring equipment manufacturers and suppliers, Condition Monitoring contractors, and organisations employing Condition Monitoring techniques Contact Memory - A New Tool for Managing Lubrication and Oil Analysis Activities Contamination Monitoring For Maximum Uptime Defining and Executing Excellence in Lubrication Defining And Maintaining Fluid Cleanliness For Maximum Hydraulic Component Life This article, an extract from the first chapter of Brendan Casey's excellent book "Insider Secrets to Hydraulics" gives some highly practical tips for extending the life of, and increasing the reliability of, your hydraulic systems. - requires free Adobe Acrobat Reader for viewing. Diagnosing a Low-Speed Gearbox Problem: A PREDICT/DLI Case History - requires free Adobe Acrobat Reader for viewing. Effective filtration and analysis of oils in mechanical systems can extend equipment life and reduce operating costs Establishing a Lubricant Analysis Program An effective Lubricant Analysis Program must have the following elements: Defined Objectives, Effective Program Design, Program Implementation Plan, Program Management Strategy Evaluating A Rotary Screw Lubricant Before You Buy The goal of this article is two-fold; First, to outline what tests should be included on a product data sheet for an air compressor lubricant, secondly, to define each of these tests and associate them to what primary function they effect in regard to performance in a rotary screw compressor. I’ll also present to you some additional screening tests that pertain to this application. The KISS method is used throughout this paper. The KISS method, if you don’t already know, stands for, keep it simple-son. That works for me, hopefully it will work for you too!!

http://www.plant-maintenance.com/maintenance_articles_tribology.shtml (2 of 5) [5/12/2004 11:37:51 PM] Tribology and Oil Analysis Articles

Failure Analysis: Lubrication How to diagnose lubrication failures in bearings How Rewarding is Your Lubrication Program? How To Lube Up Your FMEA Process Get specific about lubrication related problems to step up reliability and achieve lubrication excellence Increasing Reliability through Oil Analysis Oil Analysis can be a powerful tool to improve equipment reliability - but only if you ensure that the correct oil analysis test are performed, and only if you then take the appropriate corrective action. Integrating Vibration, Motor Current, and Wear Particle Analysis with Machine Operating State for On-line Machinery Prognostics/ Diagnostics Systems (MPROS) - requires free Adobe Acrobat Reader for viewing. Investigation of an In-Line Dielectric and Temperature Sensor for Oil This paper introduces a new Dielectric and Temperature Monitoring system used to monitor oil quality, oil level, and water contamination for industrial machinery applications Let's Integrate Oil Analysis and Vibration Analysis Lubrication - A strategic part of asset management As maintenance strategies are selected for managing mechanical assets, three elements should be included. A program should (1) be proactive, (2) be tailored to your company, facility, and type of equipment, and (3) include a strategic lubrication program Lubrication Program Training Did you know that training can have a big impact on machinery wear rates? This issue describes how an integrated steel mill instructed maintenance and production staff on good housekeeping practices. The result was ten-times cleaner oil and 50% reduction in abrasive wear Maximize Oil Analysis Data Density With Correctly Located Sample Points Mindconnection's Information Connection: Grease Compatibility Chart

http://www.plant-maintenance.com/maintenance_articles_tribology.shtml (3 of 5) [5/12/2004 11:37:51 PM] Tribology and Oil Analysis Articles

Minilab Testing Grease Samples More than half the rotating machinery in your plants is lubricated with grease. Many plants use vibration analysis and ultrasonic analysis to nondestructively inspect the mechanical condition and lubrication status of grease lubricated bearings, but there is also a method for testing grease extracted from a bearing for evidence of contamination and wear using on-site instruments. This method can be performed using either a CSI 5200 Minilab or CSI's particle counter and microscopic wear debris analysis Oil Analysis - How to Get Started What should you do to get an oil analysis or a tribology program started? Oil Analysis Statistics Show Frequencies of Common Problems Oil Analysis Success at a Power Generation Station Operation Cleanup: The First Step to Contamination Control is a Clean New Oil Supply Optimizing the Quality of Data During Oil Sampling Physical and Chemical Properties of Mineral Oils That Affect Lubrication Recognition of these properties is useful for designing lubrication systems, choosing lubricating oils, diagnosing lubrication, friction and wear problems, and selecting appropriate testing methods Putting On-Site Oil Analysis to Work Reliability Engineering Snapshot - Lubrication When an oil vendor promises that their open gear lubricant can handle any environment, they mean it; but can the gear handle it too? Beware of contamination. Reliability-Centered Maintenance and its Meaning to the Oil Analysis Professional Sampling Procedures Build a Solid Foundation for Oil Analysis Success Silicon...Enemy Number 1 Spectroscopy for Large Particle Measurement The First Step to Contamination Control is a Clean New Oil Supply The Hidden Cost of Oil Changes It turns out that hidden costs can outweigh the acquisition cost for industrial lubricating oils. http://www.plant-maintenance.com/maintenance_articles_tribology.shtml (4 of 5) [5/12/2004 11:37:51 PM] Tribology and Oil Analysis Articles

The Role of Oil Analysis Within an Asset Optimization Program The Three Dimensions of Fluid Condition Management The Visual Crackle - A New Twist to an Old Technique This machine screams for grease High-performance grease replaces wheel oil to help reduce roller coaster's cost per ride Understanding Paper Machine Oil Deposits Understanding the Basics of Grease Since lubricating oil can oxidize, so can the base oil in grease. When the grease oxidizes, it usually darkens; there is a build-up of acidic oxidation products, just as in other lubrications. These products can have a destructive effect on the thickener, causing softening, oil bleeding, and leakage. Because grease does not conduct heat easily, serious oxidation can begin at a hot point and spread slowly through the grease. This produces carbonization and progressive hardening or crust formation. All things considered the effects of oxidation is more harmful in grease than in oil. Using Oil Analysis to Monitor the Depletion of Defoamant Additives Using Oil Color as a Field Test What Particles Mean and Why They Need to be Monitored and Controlled What Particles Mean and Why They Need to be Monitored and Controlled Why Oil Analysis Should Be Performed On-Site X-Ray Fluorescence Spectroscopy - The Next Generation of Wear Debris Analysis

http://www.plant-maintenance.com/maintenance_articles_tribology.shtml (5 of 5) [5/12/2004 11:37:51 PM] Technical Articles - Turbine Maintenance Plant Maintenance Resource Center

Technical Articles - Turbine Maintenance

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Articles on Turbine Maintenance

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Condition Monitoring of Steam Turbines by Performance Analysis The paper outlines with some examples some condition monitoring techniques which have contributed to running some large machines for up to 17 years without opening high pressure sections Designing Boolean Condition Turbine Trips

http://www.plant-maintenance.com/maintenance_articles_turbines.shtml [5/12/2004 11:37:52 PM] Valves and Control Valves Articles Plant Maintenance Resource Center

Valves and Control Valves Articles

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Articles on Valves and Control Valves

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Control Valve Actuator Operating Modes Control Valve Concepts Control Valve Flow Characteristics Control Valve Packing Control Valve Seat Leakage Classifications Control Valve Terminology Control Valve Tips & Tricks Control Valves - Flow Recovery Coefficient Control Valves - Pressure Recovery Factor Improving Valve Life and Operating Efficiency The Easy Way Eight often-overlooked valve maintenance basics Improving Valve Life and Operating Efficiency the Easy Way Here are eight often-overlooked valve maintenance basics Positioner and Actuator Operating Modes Valve Positioners Valve Values Focus on valve performance reduces corrosive leaks and results in major savings for chemical plant

Copyright 2003, The Plant Maintenance Resource Center . All Rights Reserved. http://www.plant-maintenance.com/maintenance_articles_valves.shtml (1 of 2) [5/12/2004 11:37:52 PM] Valves and Control Valves Articles

Revised: Wednesday, 05-May-2004 20:57:26 CDT Privacy Policy

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We respect your individual privacy. That is why we have adopted this Privacy Policy, which embodies our commitment to the protection of your privacy through adherence to fair electronic information practices. This Privacy Policy puts you, the individual, in control of how your personal information is processed, and you have our promise that we will not electronically process your personal information in any way that is incompatible with this Privacy Policy. This Privacy Policy protects your privacy by informing you about the types of personal information the Plant Maintenance Resource Center collects about you through its Web site;

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Personal Information Collected

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We use your IP address to help diagnose problems with our server, and to administer our website. Your IP address is used to help us to gather demographic information, but does not reveal your individual identity. We may also use information gathered from IP addresses to statistically analyze site usage, and to improve our marketing, content, and promotional efforts.

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Revised: Thursday, 22-Jan-2004 00:09:43 CST Privacy Policy

http://www.plant-maintenance.com/privacy_policy.shtml (5 of 5) [5/12/2004 11:37:53 PM] Pollutant Glossary A glossary of the terms that are used whenever pollutants are discussed 15-6

The sealing of rotating fluid handling equipment and the ultimate containment of possible pollutants are two subjects that go "hand in hand". Since we are involved in these subjects, we might as well learn the language; so here is a list of the common pollution terms you may encounter. I was given this glossary without an identification of the author. It appears to be a government publication from the Environmental Defense Fund.

Glossary (Environmental Defense Fund?)

Acute Toxicity

Negative health effects from a single dose or exposure to a toxic chemical or other toxic substance.

Adverse Health Effect

Abnormal or harmful effect to an organism (e.g., a person) caused by exposure to a chemical. It includes results such as death, other illnesses, altered body and organ weights, altered enzyme levels, etc.

Ambient

Surrounding, as in the surrounding environment. The medium surrounding or contacting an organism (e.g., a person), such as outdoor air, indoor air, water, or soil, through which chemicals or pollutants can be carried and can reach the organism.

Antagonism (chemical)

When the adverse effect or risk from two or more chemicals interacting with each other is less than what it would be if each chemical was acting separately.

Attainment Area

A geographic area that meets the National Ambient Air Quality Standard (NAAQS) is called an attainment area. An area with too much of a pollutant to meet the NAAQS for that pollutant is called a non-attainment area.

NAAQSs are concentration levels for each of six criteria air pollutants, above which adverse effects on human health may occur. The six criteria pollutants are used as indicators of air quality.

Authoritative Scientific or Regulatory Organization

http://www.mcnallyinstitute.com/15-html/15-06.htm (1 of 14) [5/15/2004 9:21:34 AM] Pollutant Glossary Organizations that either have regulatory authority over a subject (such as control of certain chemicals in certain contexts) or are widely recognized as using the best available scientific practices and peer review processes in developing their policies and recommendations about that subject. Scorecard's lists of recognized health hazards come from lists already put together by authoritative organizations.

Benzene-Equivalents

Scorecard's common unit of comparison for carcinogens, so that the seriousness of a release of one carcinogen can be compared to a release of another. Scorecard's scoring system takes into account both a chemical's toxicity and the amount of exposure resulting from a release. It uses benzene as the standard for comparison and converts releases of other carcinogens into pounds of benzene-equivalents.

Bin

A range of values used for grouping purposes. In statistics, values are often grouped into bins to make generalizations, or to draw comparisons. For example, Scorecard usually places chemicals in bins based on their toxicity using 10 bins. Bin 1 includes the 10% of chemicals with the lowest toxicity, while bin 10 includes the 10% of chemicals with the highest toxicity .

Bioaccumulation

Bioaccumulation is the process by which chemicals concentrate in an organism. For example, DDT concentrates in fish and birds that eat fish. This concentration effect is expressed as the ratio of the concentration of the chemical in an organism (like a fish) to its concentration in the surrounding medium (usually water). Bioaccumulation refers to the uptake of chemicals both from water (bioconcentration) and from ingested food and sediment.

Cancer

Cancer is a group of more than 100 different diseases that occur when a cell, or group of cells, grows in an unchecked, uncontrolled, or unregulated manner. It can involve any tissue of the body and can have many different forms in each body area. Most cancers are named for the type of cell or the organ in which they begin, such as leukemia or lung cancer.

Cancer Potency Estimate

An estimate of a chemical's likelihood to cause cancer, generally derived from animal studies and extrapolated to humans.

Cancer Risk Score

How a chemical's estimated cancer risk compares with the cancer risk from other chemicals, after being

http://www.mcnallyinstitute.com/15-html/15-06.htm (2 of 14) [5/15/2004 9:21:34 AM] Pollutant Glossary converted into a common unit of comparison.

Carcinogen

A chemical or physical agent capable of causing cancer.

Cardiovascular and Blood Toxicity

The adverse effects on the heart or blood systems which result from exposure to toxic chemicals.

CAS Registry Number

A unique number assigned to a chemical by the Chemical Abstracts Service, a division of the American Chemical Society.

Chemical Carcinogenesis

Cancer caused by exposure to a chemical or chemicals.

Chemical Interaction

When two or more chemicals interact with each other, resulting in either antagonistic or synergistic effects.

Chronic Toxicity synergistic effects. Adverse health effects from repeated doses of a toxic chemical or other toxic substance over a relatively prolonged period of time, generally greater than one year.

Connective Tissue

One of the four basic types of tissue in the body; a material consisting of fibers (e.g., tendons or ligaments) that form a framework to support other body tissues (e.g., muscles).

Contaminant

Any substance or material in a system (the environment, the human body, food, etc.) where it is not normally found; or, a substance in a system where it is naturally occurring , but found in an unusually high concentration.

Dermal

http://www.mcnallyinstitute.com/15-html/15-06.htm (3 of 14) [5/15/2004 9:21:34 AM] Pollutant Glossary concentration. Referring to the skin. Dermal absorption means absorption through the skin.

Developmental Toxicity

Adverse effects on the developing child which result from exposure to toxic chemicals or other toxic substances. Adverse effects can include birth defects, low birth weight, and functional or behavioral weaknesses that show up as the child develops.

Disease Incidence

The rate of new occurrences of a disease.

Dose-Response Assessment/Relationship

The amount of a chemical that an organism (such as a person) is exposed to is called the dose, and the severity of the effect of that exposure is called the response. A dose-response assessment is a scientific study to determine the relationship between dose and response, and how much dose is correlated with how much response.

Ecological Health Ranking

How a chemical's adverse effect on plants and animals compares with that of other chemicals in a relative ranking system.

Ecological Risk Assessment

A process used to estimate how likely it is that there will adverse effects on plants or animals from other potential stress, such as the draining exposure to chemicals (or to of a wetland). The process includes problem formulation, characterization of exposure, characterization of ecological effects, and risk characterization.

Ecotoxicity

Being poisonous or harmful to plants or animals in some degree.

Endocrine Toxicity

Any adverse structural and/or functional changes to the endocrine system (the system that controls hormones in the body) which may result from exposure to chemicals. Endocrine toxicity can harm human and animal reproduction and development.

http://www.mcnallyinstitute.com/15-html/15-06.htm (4 of 14) [5/15/2004 9:21:34 AM] Pollutant Glossary

Environmental Fate

Where a substance ends up after it is released into the environment. Environmental fate depends on many factors, including transport (e.g., wind, runoff) and transformation processes (e.g.degradation).

EPA or U.S. EPA

United States Environmental Protection Agency.

Epithelial Tissue

One of the four basic tissues of the body. The cell linings covering most of the internal and external surface of the body and its organs, e.g. stomach lining.

Exposure Assessment

Identifying the ways in which chemicals may reach individuals (e.g., by breathing); estimating how much of a chemical an individual is likely to be exposed to; and estimating the number of individuals likely to be exposed.

Exposure Potential

An estimate of the total dose of a chemical received by an exposed organism (e.g., a person) or by a population, not just via one pathway or medium but from all likely pathways.

Fate and Exposure Modeling

The scientific process used to predict where chemicals "end up" after being released into the environment. For example: a chemical may be emitted into the air, but most of it might end up in groundwater, because of the chemical's particular physical properties.

Genotoxicity

The adverse health effect a chemical has on genes and chromosomes, primarily gene mutations, chromosome aberrations and changes in chromosome number. Genotoxicity may be indicative ofcancer- causing chemicals.

Good Neighbor Agreement

A Good Neighbor Agreement (GNA) is one important way that a community and a company with a facility in that community can work towards improving the environmental performance of the company's

http://www.mcnallyinstitute.com/15-html/15-06.htm (5 of 14) [5/15/2004 9:21:34 AM] Pollutant Glossary facility.

Half-life

The time in which the concentration of a chemical in the environment is reduced by half.

Hazard Identification

The first step in the risk assessment process. This step includes the identification of a chemical of concern and its potential adverse effects.

Hazard Indicator

A quantitative measurement of a chemical's hazard. Scorecard includes hazard indicators for numerous endpoints, including human health, ecological health, and combined human and ecological health. These are based on different combinations of factors, such as toxicity, persistence, and exposure potential.

Hazard Ranking

How a chemical's adverse effects compare with other chemicals in a ranking system.

Health Hazard

Adverse effects to a living organism.

Human Health Ranking

How a chemical's adverse health effects on humans compare with the same effects from other chemicals, in a ranking system.

Immunotoxicity

Adverse effects on the normal functioning of the immune system, caused by exposure to a toxic chemical. Changes in immune function could produce higher rates of infectious diseases or cancer, or more severe cases of those diseases. Immunotoxic chemicals can also cause auto-immune disease or allergic reactions.

Industrial Sector

Standard Industrial Classification (SIC) codes are a system of numerical codes that categorize industrial facilities by the type of activity in which they are engaged. For example, SIC code 2911 refers to

http://www.mcnallyinstitute.com/15-html/15-06.htm (6 of 14) [5/15/2004 9:21:34 AM] Pollutant Glossary petroleum refineries. Each code number represents an industrial sector.

Ingestion

Swallowing (such as eating or drinking). Chemicals can get into or onto food, drink, utensils, cigarettes, or hands where they can then be ingested.

Inhalation

Breathing. Once inhaled, contaminants can be deposited in the lungs, taken into the blood, or both.

Integrated Health Ranking

How a chemical's adverse human and ecological health effects compare with thoseof other chemicals, in a relative ranking system.

Kidney Toxicity

Adverse effects on the kidney, urethra or bladder caused by exposure to a toxic chemical. Some such chemicals can cause acute injury to the kidney; others can produce chronic changes that can lead to kidney failure or cancer.

Leukemia

Any of several cancers of blood-forming organs (usually bone marrow cells) which cause the uncontrolled production of abnormal white blood cells (leukocytes).

Liver and Gastrointestinal Toxicity

Adverse effects to the structure and/or function of the liver, gall bladder or gastrointestinal tract caused by exposure to a toxic chemical. The liver is frequently subject to chemical-induced injury because of its role as the body's principal site of metabolism. Chemicals that damage the liver can cause diseases such as hepatitis, jaundice, cirrhosis and cancer.

Musculoskeletal Toxicity

Adverse effects to the structure and/or function of the muscles, bones and joints caused by exposure to a toxic chemical. Exposures to coal dust and cadmium, for example, have been shown to cause adverse changes to the musculoskeletal system. Examples of musculoskeletal diseases which can be caused by exposure to toxic chemicals include the bone disorders arthritis, fluorosis, and osteomalacia.

http://www.mcnallyinstitute.com/15-html/15-06.htm (7 of 14) [5/15/2004 9:21:34 AM] Pollutant Glossary Mutagenicity

A change in the genetic material of a living organism, usually in a single gene, which can be passed on to future generations.

Nephrotoxicity

Same as kidney toxicity.

Neurotoxicity

Adverse effects on the structure or function of the central and/or peripheral nervous system caused by exposure to a toxic chemical. Symptoms of neurotoxicity include muscle weakness, loss of sensation and motor control, tremors, cognitive alterations and autonomic nervous system dysfunction.

NIOSH

The National Institute for Occupational Safety and Health, a federal agency that conducts research on occupational safety and health questions and makes recommendations to federal OSHA about new standards for controlling toxic chemicals in the workplace.

Noncancer Risk Score

How a chemical's non-cancer risk compares with the non-cancer risk from other chemicals, after being converted into a common unit of comparison.

OECD

The Organization of Economic Cooperation and Development (OECD), a Paris-based intergovernmental organization with 29 member countries. A forum in which governments can develop common solutions to various social problems, including issues of toxic chemical management.

Ozone Depleting Substance Ozone in the stratospheric layer of the Earth's atmosphere keeps 95-99% of the Sun's ultraviolet radiation from striking the Earth. Various chemicals deplete the ozone layer by accelerating processes that destroy ozone, increasing the amount of ultraviolet radiation that reach the surface. This radiation can cause genetic damage, eyedamage and damage to marine life.

Persistence

In Scorecard, persistence generally refers to environmental persistence: the length of time a chemical stays in the environment, once introduced. Persistent chemicals do not break down easily in the

http://www.mcnallyinstitute.com/15-html/15-06.htm (8 of 14) [5/15/2004 9:21:34 AM] Pollutant Glossary environment.

Persistent Organic Pollutants (POPs)

Persistent Organic Pollutants (POPs) are chemicals, chiefly compounds of carbon, that persist in the environment, bioaccumulatethrough the food chain, and pose a risk of causing adverse effects to human health and the environment.

Photosensitization

Sensitization or heightened reactivity of the skin to sunlight, usually due to the action of certain drugs.

Pollution Prevention

An approach that avoids creating toxic chemical emissions and waste in the first place; it reduces the amount of toxic chemicals that businesses need to use in their operations.

Postnatal

Occurring sometime after birth, with reference to the newborn infant.

Prenatal

Preceding birth, with reference to the fetus.

Proposition 65

Formally known as the Safe Drinking Water and Toxics Enforcement Act , Proposition 65 was enacted in California by direct ballot initiative in November 1986. Generally, it requires warnings to citizens when they are exposed to chemicals known to cause cancer or birth defects or other reproductive harm, and also forbids the discharge of those same chemicals into sources of drinking water in California.

Recognized Human Health Hazard

Authoritative national and internationalscientific and regulatory agencies have identified some chemicals that cause specific adverse health effects with enough certainty to consider the effect a recognized hazard of the chemical. To date, such efforts have been focused on cancer, reproductive toxicity, and developmental toxicity. Scorecard uses lists developed under California's Proposition 65 (which combine the hazard identification efforts of various authoritative bodies) as its primary reference for identifying these chemicals.

http://www.mcnallyinstitute.com/15-html/15-06.htm (9 of 14) [5/15/2004 9:21:34 AM] Pollutant Glossary Reference Concentration (RfC)

An estimate of the daily inhalation dose, expressed in terms of an ambient concentration, that can be taken daily over a lifetime without appreciable risk.

Reference Dose (RfD)

An estimate of the daily ingestion dose, expressed in terms of amount per unit of body weight, that can be taken daily over a lifetime without appreciable risk.

Reproductive Toxicity

Adverse effects on the male and/or female reproductive systems caused by exposure to a toxic chemical. Reproductive toxicity may be expressed as alterations in sexual behavior, decreases in fertility or fetal loss during pregnancy. Some official definitions of reproductive toxicity, for example in California's Proposition 65, include developmental toxicity as part of reproductive toxicity.

Respiratory Toxicity

Adverse effects on the structure or functionof the respiratory system caused by exposure to a toxic chemical. Respiratory toxicants can produce a variety of acute and chronic pulmonary conditions, including local irritation, bronchitis, pulmonary edema, emphysema and cancer.

Risk

The probability that damage to life, health, and/or the environment will occur as a result of a given hazard (such as exposure to a toxic chemical). Some risks can be measured or estimated in numerical terms (e.g., one chance in a hundred).

Risk Assessment

An organized process used to describe and estimate the amount of risk of adverse human health effects from exposure to a toxic chemical (how likely or unlikely it is that the adverse effect will occur). How reliable and accurate this process is depends on the quantity and quality of the information that goes into the process. The four steps in a risk assessment of a toxic chemical are hazard identification, dose- response assessment, exposure assessment, and risk characterization.

Risk Assessment Value

Risk assessment values are numbers that help define the level of health risk, both cancer and noncancer, posed by a toxic chemical. They are derived from dose-response assessments of animal or human studies

http://www.mcnallyinstitute.com/15-html/15-06.htm (10 of 14) [5/15/2004 9:21:34 AM] Pollutant Glossary that indicate a chemical cancause an adverse health effect.

Risk Characterization

An organized process used to evaluate, summarize, and communicate information about the likelihood of adverse health or ecological effects from particular exposures to a toxic chemical in the environment, i.e. how individuals or populations may be affected. It includes discussion of the kind of evidence it uses and how strong that evidence is. Risk characterization is the final step in the process of risk assessment.

Risk Management

The process of actually trying to reduce risk, e.g., from a toxic chemical, and/or of trying to keep it under control. Risk management involves not just taking action, but also analyzing and selecting among options and then evaluating their effect.

Route of Exposure

The avenue by which a chemical comes into contact with an organism (such as a person). Possible routes include inhalation, ingestion, and dermal contact.

Safety Assessment

The process of evaluating the safety (or lack of safety) of a chemical in the environment based upon its toxicity and current levels of human exposure.

Screening Level

Screening level information about a chemical's toxicity or exposure potential is derived from readily available information using methods that do not require extensive analyses to support preliminary evaluations of chemical safety. Screening level information is useful and necessary for ranking potential problems, directing more detailed investigations, and taking preventative action.

Screening Risk Assessment

A risk assessment performed using available data and many assumptions to identify toxic chemical releases that have a higher probability of posing health risks. If potential health risks are identified, further investigation or risk reducing actions may be warranted.

SIC Code

Standard Industrial Classification (SIC) codes are a system of numerical codes that categorize industrial

http://www.mcnallyinstitute.com/15-html/15-06.htm (11 of 14) [5/15/2004 9:21:34 AM] Pollutant Glossary facilities by the type of activity in which they are engaged. For example, SIC code 2911 refers to petroleum refineries. All companies conducting the same type of business, regardless of their size, have the same SIC code. The basic SIC code is two digits long.

SIDS

The Screening Information Data Set createdby the member countries of the Organization for Economic Cooperation and Development (OECD) in 1990, for purposes of screening high-production-volume chemicals used in those countries (including the U.S.). The purpose of the SIDS program is to complete initial screening tests on those chemicals to identify their potential hazards to human health and the environment, so that risk assessments can then be done for the chemicals with sufficient hazard potential. The data set is a list of the tests and other information about a chemical that OECD considers to be the necessary minimum for purposes of this preliminary screening.

Skin and Sense Organ Toxicity

Adverse effects on the skin or sensory organs caused by exposure to a toxic chemical. Sense organs include eyes, ears, etc.

Suspected Human Health Hazard

These are hazards to human health from a chemical that are indicated by some scientific evidence, but that have not been conclusively determined by an authoritative scientific or regulatory organization. Scorecard uses numerous reports in the scientific or regulatory literature, and information abstracted from major toxicological databases, as its sources for identifying chemicals with suspected human health hazards of different kinds. Inclusion of a chemical on a "suspected" list should be viewed as a preliminary indication that the chemical may cause this effect, rather than a definitive finding that it does.

Synergism (chemical)

When the adverse effect or risk from two or more chemicals interacting with each other is greater than what it would be if each chemical was acting separately.

Threshold

A level of chemical exposure below which there is no adverse effect and above which there is a significant toxicological effect.

Toluene-Equivalents

Scorecard's common unit of comparison for non-carcinogens, so that the seriousness of a release of one non-carcinogen can be compared to a release of another. Scorecard's scoring system takes into account

http://www.mcnallyinstitute.com/15-html/15-06.htm (12 of 14) [5/15/2004 9:21:34 AM] Pollutant Glossary both a chemical's toxicity and the amount of exposure resulting from a release. It uses toluene as the standard for comparison and converts releases of other non-carcinogen into pounds of toluene- equivalents.

Total Hazard Value

A quantitative value representing the total hazard of a chemical substance, derived by integrating the chemical's human health effects, ecological effects, and exposure potential.

Toxic Equivalency Potentials

How a chemical's adverse human health effects compare with those of other chemicals, after being converted into a common unit of comparison (Scorecard uses benzene-equivalents for carcinogens and toluene-equivalents for non-carcinogens).

Toxicity

The extent, quality, or degree of being poisonous or harmful to humans or other living organisms.

Toxicity Weight

How a chemical's toxicity - either chronic, acute, or both - compares with other chemicals in a relative ranking system.

TRI

Toxics Release Inventory. Under Section 313 of the Emergency Planning and Community Right-To- Know Act of 1986 (EPCRA), certain manufacturing facilities are required to report the amounts of approximately 650 toxic chemicals that they release into the environment or produce as waste. The TRI inventory is, at present, the only source of information used by Scorecard on environmental releases of toxic chemicals and waste management of those chemicals.

TRI Chemicals

A list of about 650 toxic chemicals or chemical categories included in the Toxics Release Inventory (TRI). In general, TRI chemicals are ones that U.S. EPA has found can be reasonably anticipated to cause acute or chronic adverse human health effects, or adverse environmental effects.

TRI Facilities

Facilities that are required to report their environmental releases and chemical waste management of a

http://www.mcnallyinstitute.com/15-html/15-06.htm (13 of 14) [5/15/2004 9:21:34 AM] Pollutant Glossary prescribed list of approximately 650 toxic chemicals to the Toxics Release Inventory (TRI). There are over 20,000 facilities included in the TRI in 1995.

TSCA

The Toxic Substances Control Act (TSCA) of 1976. In theory, this law gave U.S. EPA the power to test, regulate, and screen nearly all chemicals produced or imported into the United States. However, after more than two decades, TSCA's promise is almost entirely unrealized.

Volatility

A chemical's tendency to evaporate into the air, usually measured in units of Pascals, atmospheres, or pounds per square inch. Chemicals with high volatility tend toevaporate readily.

Weight of Evidence

The evaluation of published information about a chemical's toxicity and exposure potential that leads to a conclusion about that chemical's safety or hazard. Important factors include the adequacy and number of available studies; the consistency of results across studies; and the biological plausibility of dose- response relationships.

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http://www.acronymfinder.com/ [5/15/2004 9:22:59 AM] Glossary of Bearing Terms

Glossary of Bearing Terms

This information reprinted courtesy of IBT, Inc.

A.B.E.C. Annular Bearing Engineering Committee. Used as prefix for tolerance grades of bearings as set up by this committee.

A.B.E.C. 1-3-5-7-9 Annular Bearing Engineers Committee classes or grades of ball bearing precision.

A.F.B.M.A. The Anti-Friction Bearing Manufacturers Association. They have set up standards for the bearing industry.

Adapter Assembly Assembly consisting of adapter sleeve, locknut and lockwasher.

Adapter Sleeve Axially slotted sleeve with cylindrical bore, tapered outside surface and male screw thread at small end used with locknut and lockwasher for mounting of bearings with tapered bore on cylindrical outside surface of shaft. Also called pull-type sleeve.

Aircraft Bearing A term applied generally to bearings used by the aircraft industry or the Air Force.

Airframe Bearing A bearing designed for use in the control systems and surfaces of aircraft.

Angular Contact Bearing A type of ball bearing whose internal clearances and ball race locations are such as to result in a definite contact angle between the races and the balls when the bearing is in use.

Annular Ball Bearing A rolling element bearing designed primarily to support a load perpendicular to the shaft axis. Also: Radial Type Bearing.

Anti-friction Bearing Commonly used term for rolling element bearing.

Axial In the same direction as the axis of the shaft.

Axial Internal Clearance In ball or roller bearing assembly, total maximum possible movement parallel to bearing axis of inner ring in relation to outer ring. Also called bearing end play.

Axial Load

http://www.maintenanceresources.com/ReferenceLibrary/Bearings/gobt.htm (1 of 9) [5/15/2004 9:23:10 AM] Glossary of Bearing Terms

Load exerted parallel to the axis of the shaft on which the bearing is mounted, also called thrust load.

Axis An imaginary line running through the center of a shaft on which a bearing is mounted.

Ball A spherical rolling element.

Ball Bearing A bearing using balls as the rolling elements.

Ball Cage A device which partly surrounds the balls and travels with them, the main purpose of which is to space the balls. Also Separator: Retainer: Ball Spacer.

Ball Complement Number of balls used in a ball bearing.

Ball Contact Area of contact between raceway and ball.

Ball Diameter The dimension measured across the ball center.

Ball Pocket A drilled, stamped, or molded receptacle that holds the ball in a cage.

Basic Dynamic Load Rating Basic dynamic load rating, Cr, is the calculated constant radial load (thrust load for thrust bearings) which a group of identical bearings with stationary outer rings can theoretically endure for rating life of 1 million revolutions of inner ring.

Bore The smallest internal dimension of inner or outer ring or separator. Also, the surface of the inner ring that fits against the shaft.

Boundary Dimensions Dimensions for bore, width, outside diameter and corner radius.

Cage See Ball Cage.

Cam Follower See Track roller

Cartridge Bearing An extra wide double shielded or sealed bearing designed to increase grease capacity of bearing.

http://www.maintenanceresources.com/ReferenceLibrary/Bearings/gobt.htm (2 of 9) [5/15/2004 9:23:10 AM] Glossary of Bearing Terms

Concentric Having the same center.

Cone Inner ring of tapered roller bearing.

Conrad Standard single row deep-groove bearing named for the inventor of its assembly method, Joseph Conrad.

Contact Angle Formed by a line drawn between the areas of ball and ring contact and a line perpendicular to the bearing axis.

Counterbored Ball Bearing Portion of one race shoulder turned and ground away to facilitate assembly with a greater number of balls. A non- separable ball bearing with one side of the raceway removed from either or both rings to facilitate manufacturing assembly. Normally the outer ring is counterbored.

Double Row Bearing A bearing with two rows of rolling elements.

Double Row Maximum Capacity A bearing that has a solid inner and outer with two raceways and filling notches to permit the maximum number of balls to be inserted.

Drawn Cup Needle Roller Bearing Needle roller radial bearing with thin pressed steel outer ring (drawn cup), which may have one closed end or both ends open. Usually employed without inner ring.

Duplex Bearing A duplex bearing is a bearing with controlled axial location of faces of inner and outer rings which makes this bearing suitable for mounting in various combinations with one or more bearings controlled in the same manner.

Dynamic Load A load exerted on a bearing in motion.

Eccentric Not having the same center.

End Play The axial play of the outer ring in a bearing. The measured maximum possible movement parallel to bearing axis of the inner ring in relation to outer ring.

External Race The ball path on an inner ring. Also - Inner Raceway, Inner Ring Raceway.

Face The side surface of a bearing. See also Thrust Face.

http://www.maintenanceresources.com/ReferenceLibrary/Bearings/gobt.htm (3 of 9) [5/15/2004 9:23:10 AM] Glossary of Bearing Terms

Fillet Radius The corner dimension in a bearing housing that the bearing external corner radius or chamfer must clear.

Filling Notch A slot or notch cut in the shoulder of a ring to allow the loading of the maximum number of balls. Also Filling Notch; Loading Groove.

Finish A term usually applied to the last machining operation on any surface of a bearing, such as "Finish O.D., " "Finish bore, " etc.

Fit The amount of internal clearance in a bearing. Fit can also be used to describe shaft and housing size and how they relate to the bore or outside diameter.

Fixed Bearing Bearing which positions shaft against axial movement in both directions.

Floating Bearing Bearing designed or mounted so as to permit axial displacement between shaft and housing.

Full Complement Bearing Rolling bearing without cage in which sum of clearances between rolling elements in each row is less than the diameter of rolling elements and small enough to give satisfactory function of bearing.

Hardening Process of heating parts to a high temperature and then quenching in oil, water, air, or solution.

Heading Rivets Process of hitting rivets in a press to form the heads.

Housing, Bearing The opening in which a bearing is contained in a machine. The part of a machine that contains this opening.

Housing Fit Amount of interference or clearance between bearing outside surface and housing bearing seat.

Hydraulic Nut Collar temporarily fixed to shaft which incorporates hydraulic annular piston to transmit axial mounting or dismounting force to bearing inner ring.

ISO International Standards Organization.

Inch Dimension Bearing A bearing having boundary dimensions made to integral or/and fractional inch figures rather than metric figures.

http://www.maintenanceresources.com/ReferenceLibrary/Bearings/gobt.htm (4 of 9) [5/15/2004 9:23:10 AM] Glossary of Bearing Terms

Inner See Inner Ring

Inner Ring The inner part of a bearing that fits on a shaft and contains the external raceway for the rolling elements. Sometimes the shaft is stationary and the housing rotates.

Inner Ring Raceway See External Race.

Internal Clearance See Radial Clearance.

Internal Race The ball or roller path on the bore of the outer ring. Outer Ring Raceway. Outer Raceway.

Land Commonly called the O.D. of the inner and the I.D. of the outer.

Lapping An abrading process for refining the surface finish and the geometrical accuracy of a surface.

Life "Life" of individual rolling bearing is the number of revolutions (or hours at some given constant speed) which bearing runs before first evidence of fatigue develops in the material of either ring or washer or any of rolling elements.

Limits Maximum and minimum allowable dimensions, resulting from the application of predetermined tolerances to a specified dimension.

Lock Nut A nut used in combination with a lock washer to hold a bearing in place on a shaft.

Lock Washer A washer with tongue and prongs to hold a lock nut in place.

Locking Collar, Concentric Ring fitting over extended inner ring of insert bearing and having setscrews which pass through holes in inner ring to make contact with shaft.

Locking Collar, Self Ring having recess on one side which is eccentric in relation to bore and fits over equally eccentric extension of inner ring insert bearing. Collar is turned in relation to inner ring until it locks and then secured to shaft by tightening of setscrews.

Loose Fit A fit or fit up of inner ring, balls, and outer ring which results in the existence of appreciable radial clearance.

http://www.maintenanceresources.com/ReferenceLibrary/Bearings/gobt.htm (5 of 9) [5/15/2004 9:23:10 AM] Glossary of Bearing Terms

Maximum Capacity Bearing A bearing with filling notches to allow the loading of the maximum number of balls.

Misalignment Lack of parallelism between axis of rotating memeber and stationary member.

Needle Roller Cylindrical roller of small diameter with large ration of length to diameter. Generally accepted that length is between three and ten times diameter which is usually less than 5 mm.

O.D. Outer Diameter; Outside Diameter.

Outer See Outer Ring.

Outer Raceway See Internal Race.

Outer Ring The outer part of a bearing that fits into the housing and contains the internal raceway for the rolling elements.

Outer Ring Raceway See Internal Race.

Pocket The portion of a cage shaped to hold the ball or roller. Also Ball Pocket; Roller Pocket.

Preload An internal loading characteristic in a bearing which is independent of any external radial and/or axial load carried by the bearing.

Prelubricated Bearing A shielded, sealed, or open bearing originally lubricated by the manufacturer.

RBEC-1, -5 Class or degree of precision of anti-friction roller bearings.

Raceway The ball or roller path; cut in the inner and outer ring in which the balls or rollers ride. Also Guide Path; Race; Ball Path; Roller Path.

Raceway Diameter Inner Ring -- the outer dimension across the diameter from raceway bottom to raceway bottom. Outer Ring -- the inner dimension across the diameter from raceway bottom to raceway bottom.

http://www.maintenanceresources.com/ReferenceLibrary/Bearings/gobt.htm (6 of 9) [5/15/2004 9:23:10 AM] Glossary of Bearing Terms

Radial Clearance The radial internal clearance of a single row radial contact ball bearing is the average outer ring race diameter, minus the average inner ring race diameter, minus twice the ball diameter.

Radial Load A load exerted perpendicular to the axis.

Radial Play See Radial Clearance.

Radial Type Bearing In general, a rolling element bearing primarily designed to support load perpendicular to the axis. Also: Annular Bearing.

Rating Life L10 of group of apparently identical bearings is the life in millions of revolutions that 90% of the group will complete or exceed.

Relieved End Roller Roller with slight modification of diameter at ends of outside surface to reduce stress concentrationat contacts between rollers and raceways.

Retainer See Ball Cage.

Riveted Type Ball Cage A type of cage in which the two halves are riveted together around the balls after the balls have been assembled in the rings.

Runout, of Assembled Bearing Displacement of surface of bearing relative to fixed point when one raceway is rotated with respect to other raceway.

Seal A soft synthetic rubber washer with a steel core fixed in the outer ring (in the seal groove) in contact with the inner ring to retain lubricant and keep out contamination.

Self Aligning Ball Bearing Spherical outside diameter ball bearing which can accommodate initial angular misalignment between the outer ring and its mating spherical aligning ring or housing seat.

Separable A bearing that may be separated completely or partially into its component parts.

Separator See Ball Cage.

Shaft Fit

http://www.maintenanceresources.com/ReferenceLibrary/Bearings/gobt.htm (7 of 9) [5/15/2004 9:23:10 AM] Glossary of Bearing Terms

Amount of interference or clearance between bearing inside diameter and shaft bearing seat outside diameter.

Shield A metal formed washer attached to the outer ring and set so it rides close to, but not contacting, the inner ring, to retain lubricant and prevent contamination.

Shoulder The side of a ball race, also a surface in a bearing application or shaft which axially positions a bearing and takes the thrust load.

Single Row Bearing with one row of rolling elements.

Snap Ring A removable ring used to axially position a bearing or outer ring in a housing. Also used as a means of fastening a shield or seal in a bearing.

Solid Cage A solid ring type separator used in a radial or angular contact type bearings.

Spacer Sleeve or sleeves serving to space different bearings on same shaft or different rows of rolling elements in multi-roll bearing.

Spherical Roller Bearing Self-aligning, radial rolling bearing with convex rollers or concave rollers as rolling elements. With convex rollers outer ring has spherical raceway, with concave rollers inner ring has spherical raceway.

Standard Bearing Bearing which conforms to the basic plan for boundary dimensions of metric or inch dimensions.

Static Load A load exerted on a bearing not in motion.

Stay Rod A flat elongated rivet used in the cages of maximum capacity bearings.

Stay Rod Type Ball Cage Type cage in which the two halves are held together with special stay rod rivets.

Thrust Load See Axial Load.

Thrust Bearing A bearing designed primarily for thrust loads.

Thrust Face

http://www.maintenanceresources.com/ReferenceLibrary/Bearings/gobt.htm (8 of 9) [5/15/2004 9:23:10 AM] Glossary of Bearing Terms

Face of thrust bearing against which housing or shaft shoulder pushes.

Tolerance The range between two limiting sizes as a means of specifying the degree of accuracy. The amount a given bearing dimension may vary from specifications. The difference between the upper and lower limits of a dimension or a specification. A means of specifying the degree of accuracy.

Track Roller Radial roller bearing with heavy section outer ring, intended to roll on track, a.k.a. cam follower.

Wide Inner Ring Bearing Bearing with inner ring extended on one or both sides in order to achieve greter shaft support and permit addition of locking device and provide additional space for sealing devices.

Withdrawal Sleeve Axial slotted sleeve with cylindrical bore, tapered outside surface and male screw thread at large end. Used for mounting and dismounting (by means of nut) of bearing with tapered bore on cylindrical outside surface of shaft. Also called push-type sleeve.

Return to Bearings Reference Articles Index

http://www.maintenanceresources.com/ReferenceLibrary/Bearings/gobt.htm (9 of 9) [5/15/2004 9:23:10 AM] Compressed air glossary

Compressed Air Glossary of Terms Index

Please read our disclaimer and our credits page

[INDEX] A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

Definitions A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

[ADD to the glossary] A

A&I A&R Absolute efficiency Absolute filtration rating Absolute micron rating Absolute pressure Absolute temperature Absolute viscosity Absolute zero Absorb Absorbent filter AC Acidity ACFM ACT Activated alumina ACTR Actual capacity

http://www.impactrm.com/glossary/ (1 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Adiabatic compression Adiabatic efficiency Adsorb Adsorbent filter Adsorptive filtration Aeration Aerosol Aftercooler Aftercooling Air Air actuator Air amplifier Air bearing Air borne Air brush Air bubble technique Air chisel Air cooled compressor Air curtain Air cylinder Air dryer Air entrainment Air flow Air horn Air knife Air leak Air lock Air motor Air nozzle Air padding Air preheater Air pressure Air pump Air receiver Air shaft Air station module Air whistle ALT Altitude

http://www.impactrm.com/glossary/ (2 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Alternating current (AC) Amagat's law Ambient Ambient environment Ammonia Amonton's law AMP Ampere(AMP) Ancillary equipment Anhydrous Anion ANLG ANR Anti pulsation tank Anti re-entrainment sock AP A.P.I. Approach temperature Artificial demand ASHRAE ASL A.S.M.E. Asset monetization A.S.T.M. ATA ATM Atmosphere Atmospheres absolute(ATA) Atmospheric boundry level Atmospheric dew point Atmospheric gases backfilling Atmospheric inversion Atmospheric pressure Atomize Attenuation Automatic sequencer Avogadro's law Axial compressor

http://www.impactrm.com/glossary/ (3 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary B

BA Back pressure Bag blinding Bag filter Bag house Balanced valve Bar Barometric pressure Bara Barg Base air requirement Base plate Bead ring Bernoulli's principle Beta ratio BHP Bicarbonate BLDN Blowdown Blower Blow off control BLWR Body Bonnet Boolean logic Booster Booster compressor Bowl Boyle's law BP Brake horse power Branch lines Breakdown maintenance Breaker

http://www.impactrm.com/glossary/ (4 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Breaking pressure Breather Breathing air Bridging British thermal unit Brownian diffusion BSPP BSPT BTU Bubble Built-in-dirt Built up back pressure Bulk specialty gas supply Bumper Buna N Burst pressure By pass By pass valve

Can velocity Cap Capacity Capacity filtration Capacity gauge Capillary tube Cap tube Carbonate Carbon dioxide Carbon monoxide Carbon residue Casing CAS number CEFAPP

http://www.impactrm.com/glossary/ (5 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Celsius Center tube Centrifugal compressor Certificate of analysis Certificate of conformance CFM CGA Charle's law Chatter Chip control Chipping hammer Check valve Chlorine Chlorofluorcarbons Choke Clarion Cleanable Cleanliness level Clean room Clean pressure drop Clean water act Clearance Clearance pocket Clevis Closed loop system CNG Coalescing filter Code Coefficient of discharge Cogeneration Cold differential test procedure Cold start Collapse Collapse pressure Compensator Composition of air Compressed Compressed air Compressed air challenge

http://www.impactrm.com/glossary/ (6 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Compressed gas Compressibility Compressibility factor Z Compression efficiency Compression Isothermal Compression ratio Compressor Compressor module Compressor station Computer control Condensate Condenser Conduction Connector Constant speed control Contaminant Contaminant capacity Contaminant failure Control valve Convection Convolution Coolant Cooling tower Coriolis force CPM Cracking Critical pressure Critical speed Critical temperature Crosshead compressor Crosshead assembly Crosshead loading CSA CTD Cubic feet per minute (CFM) cu m/sec Cut in cut out pressure Cycle Cycle time

http://www.impactrm.com/glossary/ (7 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Cylinder Cyclone Cyclone separator

Dalton's law DC Dead end pressure Deairentrainment Degrees Celsius (°C) Degrees Fahrenheit (°F) Degrees Kelvin (°K) Degree Rankine (°R) Degree Réaumur (°Ré) Degree of intercooling Degree of saturation Deliquescent Deliquescence Delta P Delta T Demand Demand side management (DSM) Demulsibility Density Depth filter Desiccant Design pressure Desorption Dew point Dew point cup Diaphragm Diaphragm compressor Diaphragm cooling Diaphragm routing

http://www.impactrm.com/glossary/ (8 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Differential pressure Differential pressure indicator Diffuser Digital controls Diluent Direct current Directional control valve Dirt holding capacity Disc Discharge piping Discharge pressure Discharge temperature Displacement compressor Displacement of a compressor Disposable filter DOE DOP Double acting compressor Downstream Drag Drain valve Dripleg Drive Dropleg Dry adiabatic lapse rate Dry bulb temperature Dry gas Dry unit (oil free) Dual control Duct Durometer Dust cake Dust holding capacity Duty cycle Dynamic losses Dynamic type compressors Dynamic viscosity

http://www.impactrm.com/glossary/ (9 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary E

Effective area Efficiency Efficiency compression Efficiency isothermal Efficiency mechanical Efficiency polytropic Efficiency volumetric Ejector compressor Element Emulsibility Emulsifier Emulsion End cap Energy audit Energy conservation Energy kinetic Energy storage Enrichment Enthalpy Entrainment ratios Entropy Environmental contaminant Evaporation Evaporator Exhauster Exothermic Expanders

FAD

http://www.impactrm.com/glossary/ (10 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Fatigued Ferrography Fick's law of diffusion Filter Filter breather Filter coalescing Filter efficiency Filter element Filter head Filter housing Filter inline Filter life test Filter medium Filter oil bath Filter separator Filtration First law of thermodynamics Fixed compression ratio Flange Flash point Flexible mounting Flow Flow control valve Flow diagram Flow meter Flow rate Fluidics Flushing Foot Forced draft fan Fouling Free air (FAD) FRL Frost point Full load

http://www.impactrm.com/glossary/ (11 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary

Gag Galling Gallon Gas Gas bearings Gas bypass Gas compressor Gas drying Gas laws Gate valve Gauge Gauge pressure Glycol dehydration Governor GPM Grade D breathable compressed air Gravimetric efficiency Guide Guide vane

Halocarbon Head adiabatic Header Head polytropic Head pressure Heat capacity Heat exchanger Heatless dryer Heat reactivated dryers Heat recovery High efficiency filtration High volume low pressure

http://www.impactrm.com/glossary/ (12 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Horsepower(HP) Horsepower brake BHP Horsepower gas Horsepower ideal Horsepower indicated Horsepower peak Horsepower theoretical Hot gas Hot gas bypass valve Hot start Housing Humidity Humidity specific Humidity relative HVLP HYCO Hydrocarbons Hydrogen chlorofluorocarbons (HCFC) Hygroscopic cells

IBV ICFM I.D. Ideal gas Ideal multi stage compression IGV Immiscible Impeller Inches of water Inches of water gauge Incremental air fee Incremental air requirement Indicated power Indicator card

http://www.impactrm.com/glossary/ (13 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Indicator pressure Induced draft Inducer Inerting Inert gas Inertia base Inertia forces Influent Ingested contaminants Inlet pressure Inlet temperature Inlet throttle Inline filter Insolubles Instrument air Intake filter Intake filter silencer Intank check valve Intercooler Intercooling Internal energy Ideal gas International Organization for Standardization Irreversible process Isentrop Isentropic compression Isentropic efficiency Isentropic power consumption ISO Isobar Isochor Isotherm Isothermal compression Isothermal efficiency Isothermal power consumption

http://www.impactrm.com/glossary/ (14 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary

Jackleg Jack hammer Jet Joule Joule effect Joule Thompson effect Jounce Journal Journal bearing JTPF JTPM

Kelvin(K) KG/CM²A Kickout type clutch Kilo Kilobar(kb) Kilowatt(kW) Kilowatt hour(kWh) Kinematic viscosity Kinetic energy Knock out kPa K value kW kWh

http://www.impactrm.com/glossary/ (15 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary

L/sec Labyrinth compressor Lacquer Langelier's index Laser gas lb lb/hr Leak air Leak detector ultrasonic Lift Lift bag Linear actuator Liner Liquefied compressed gas Liquid piston Liquid ring rotary compressor Load LNG Loaded Load factor Load time Lobe Low pressure coat Lubrication Lubricator

M3/min M3/hr Mach number Manifold Man way MAWP Maximum operating pressure Mayonnaise Mechanical efficiency

http://www.impactrm.com/glossary/ (16 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary

Media Media migration Medium Membrane dryer Mesh size Micromanometer Micron Micron rating Millibar Mineral oil MMCFD Modulating control Modulating unload Moisture separator Moisture trap Molecular sieves Mole sieve Molecular theory Mottling MPCV MSDS Multistage axial compressor Multistage centrifugal compressor Multistage compressor

N cu m/min N cu m/hr Natural frequency N.B. NEC Needle gauge Needle scaler Negative pressure NEMA NFPA

http://www.impactrm.com/glossary/ (17 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Nitrox NL NM³/HR No load Nominal efficiency Nominal filter rating Nominal micron rating Noncondensables Noncooled compressor cylinders Noncorrosive gas Nonlubricated compressor Normal air Nozzle Nozzle (valves) NPT NPTT NTP

O.D. OEM Off gas Oil aerosol Oil bath filter Oil free Oil free compressor Oil-less Oil system Operating pressure Operating pressure burst Orifice OSHA Overhung type centrifugal compressor Overpressure accumulation

http://www.impactrm.com/glossary/ (18 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary

P1 P2 P3 P4 P5 Package power Palm coupling Particle density type filter Particulate type filter Paving breaker PCM PDP Peak demand Pedestal type centrifugal compressor Perfect intercooling Performance curve Permeability pH Pinion Piston displacement Pitot tube Pleated filter Pneumatic Pneumatic power Pneumatics Pneumatic tools PNEUROP oxidation test (POT) Point of use Pore Potential energy Positive displacement compressors Pounds per square inch (PSI) Pour point Power theoretical

http://www.impactrm.com/glossary/ (19 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Power wheel PPB PPBV PPM Precool Precooler Pre open warn Pressure Pressure absolute Pressure back Pressure cracking Pressure critical Pressure dewpoint Pressure discharge Pressure drop Pressure gauge Pressure inlet Pressure pot Pressure range Pressure rated Pressure regulating valve Pressure relief device Pressure rise Pressure static Pressure swing dryer Pressure system Pressure total Pressure transfer Pressure velocity Preventive maintenance Process Pseudo critical pressure PSI PSIA PSID PSIG Psychrometry PTFE Pulsation damper

http://www.impactrm.com/glossary/ (20 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Pumping Purge air Purging

Qci Qca Qcr Quick coupler

Radial compressor Ram Rebound Receivers Reciprocating compressors Recovery pressure Reduced pressure Reduced temperature Refrigerant Refrigeration dryer Regeneration Regulator Reheaters Relative clearance volume Relative humidity Relative vapor pressure Required capacity Relief valve Reversible process

http://www.impactrm.com/glossary/ (21 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Reynold's number Rings Ring sticking Rock drill ROI Rolling element Rotary actuator Rotary blowers Rotary compressors Rotary sliding vane compressors Rotor Rust prevention test

SAE Safety valve Safety relief valve Saturated air vapor mixture Saturated vapor pressure Saturation Saturation pressure Scale SCFM Screw compressor SCUBA Sea level Seals Seat Second law of thermodynamics Sequence Set pressure Shaft Shaft input Shaft sleeves Shaft speed irregularity

http://www.impactrm.com/glossary/ (22 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Sheltered set SI Silencer Silica gel Single acting Single stage compressors Single stage centrifugal compressors Siphon feed gun Sleeve Slip Slip RPM Sludge Slusher Snifting valve Sole plate Sonic flow SOP SPC Specialty gases Specific energy requirement Specific fuel consumption Specific gravity Specific heat Specific humidity Specific power Specific volume Specific weight Speed Speed of sound Spindle SRM Standard cubic foot Standard pressure and temperature (SPT) Stability Stack up Stages Standard air Standard pressure and temperature (SPT) Start stop control

http://www.impactrm.com/glossary/ (23 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary State Stem Sterile air Stonewall STP Strainer Stroke total Stroke usable Subheaders Suction pressure Supercompressibility factor Surface filtration Surge Surge limit Swept volume Synthetic gas Synthetic lubricant

T1 T3 Temperature Temperature absolute Temperature discharge Temperature inlet Temperature intake Temperature rise ratio Temperature static Temperature total Theoretical power Thermal compressor Thermal mass Thermodynamics first law of Thermodynamics second law of Thrust balancing device

http://www.impactrm.com/glossary/ (24 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Tilting pad Torque Torr Total package input power Trunk compressor Trunnion Tugger Tundish Two stage compressor Two step control TXV valve

UL Ultrasonic leak detector UNC UNF Unit type compressors Unload Unloaded horsepower Utilization factor

Vacuum pumps Valve by pass Valves Vane compressor Vane material Vapor Vaporization Vapor pressure

http://www.impactrm.com/glossary/ (25 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary Varnish V belt drive Vent loss Venturi Viscosity Viscosity index VI Volumetric efficiency Volute Voting alarm

Warn Water cooled compressors Water solubility Wet bulb temperature Wet gas Wet helical lobe unit Wicking Winch WMW WOG Work Working pressure

Xenon

http://www.impactrm.com/glossary/ (26 of 27) [5/15/2004 9:23:27 AM] Compressed air glossary

Y-Cylinder Yoke

ZDDP Zeolite Zero Zero discharge water

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Impact RM | Comments: | Last updated Friday, 7-February-2003

http://www.impactrm.com/glossary/ (27 of 27) [5/15/2004 9:23:27 AM] Impact RM Compressed Air Glossary of Terms

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Online Compressed Air Glossary Of Terms

[ INDEX ] A B C D E F G H I J K L M N O P Q R S T U V W X Y Z [ADD] Please read our disclaimer and our credits page

a A&R Absolute efficiency Absolute micron rating Absolute pressure Absolute temperature Absolute viscosity (Dynamic) Absolute zero Absorb AC Acidity ACFM ACT Activated alumina ACTR Actual capacity Adiabatic compression Adiabatic efficiency Adsorb Adsorbent filter Adsorptive filtration Aeration Aerosol Aftercooler Aftercooling Air Air amplifier Air bearing Air borne Air brush Air bubble technique Air chisel Air actuator Air cooled compressor Air curtain Air cylinder Air dryer Air entrainment Air flow Air horn Air knife Air leak Air lock Air motor Air preheater Air pressure Air pump Air receiver Air restraint bag Air shaft Air station module Air whistle ALT Altitude Alternating current (AC) Amagat's law Ambient Ambient environment Ammonia Amonton's law AMP Ampere (AMP) Ancillary equipment Anhydrous Anion ANLG ANR Anti re-entrainment sock Anti-Pulsation Tank AP A.P.I. Approach temperature Artificial demand ASHRAE Air nozzle A.S.M.E.

http://www.impactrm.com/glossary.asp (1 of 11) [5/15/2004 9:23:46 AM] Impact RM Compressed Air Glossary of Terms

ASL Asset monetization A.S.T.M. A.S.T.M. ATM Atmosphere (ATM) ATA Atmospheres absolute (ATA) Atmospheric boundry level Atmospheric dew point Atmospheric gases backfilling Atmospheric inversion Atmospheric pressure Atomize Attenuation Automatic sequencer Avogadro's law Axial compressor Abnormal failure A/D Converter ABNT AC Linearity Activated carbon Air cycling valve Air padding Air pressure amplifier Air stripping Alarm deviation Ambient compensation Ambient pressure Amplifier Analog output Anemometer Avogadros number ATC Auto Ignition Temperature (AIT) Air pressures at various sea levels Air exchange tube

b BA Back pressure Bag blinding Bag filter Bag house Balanced valve Bar Bara Barg Barometric pressure Base air requirement Base plate Bead ring Beta ratio BHP Bicarbonate BLDN Blowdown (BLDN) Blower (BLWR) Blow off control BP BLWR Body Bonnet Boolean logic Booster Booster compressor Bowl Boyle's law Brake horse power (BHP) Branch lines Breakdown maintenance Breaker Breaking pressure Breather Breathing air Bridging Brownian diffusion British thermal unit BSPP BSPT BTU Bubble Built-in-dirt Built up back pressure Bulk specialty gas supply Bumper Buna N Burst pressure By pass By pass valve Base mount compressor Ball valve Bara Barg Bernoullis principle Block diagram Breakthrough Brownian diffusion Burst pressure rating Butterfly valve Bull whip throttle control

http://www.impactrm.com/glossary.asp (2 of 11) [5/15/2004 9:23:46 AM] Impact RM Compressed Air Glossary of Terms

c Can velocity Can-annular chamber Cap Capacity Capacity filtration Capacity gauge Capillary tube Cap tube Carbonate Carbon dioxide Carbon monoxide Carbon residue Casing CAS number CEFAPP Celsius Center tube Centrifugal compressor Certificate of analysis Certificate of conformance CFM CGA Charle's law Chatter Chip control Chipping hammer Check valve Chlorine Chlorofluorocarbons (CFCs) Choke Clarion Cleanable Cleanliness level Clean room Clean pressure drop Clean water act Clearance Clearance pocket Clevis Collapse Collapse pressure CNG Closed loop system Coalescing filter Code Coefficient of discharge Cogeneration Cold differential test procedure Cold start Compensator Composition of air Compressed Compressed air Compressed air challenge Compressed gas Compressibility Compressibility factor Z Compression adiabatic Compression efficiency Compression Isothermal Compression ratio Compressor Compressor module Compressor station Computer control Condensate Condenser Conduction Connector Constant speed control Contaminant Contaminant capacity Contaminant failure Control valve Convection Convolution Coolant Cooling tower Coriolis force CPM Cracking Critical pressure Critical speed Critical temperature Crosshead assembly Crosshead compressor Crosshead loading CSA CTD Cubic feet per minute (CFM) cu m/sec Cut in cut out pressure Cycle Cycle time Cylinder Cyclone Cyclone separator Closed crankcase compressor Centigrade temperature scale Calibration procedure Closeness of control Common mode Control point CPS Continuous pump CFM Cut In PSI Cut Out PSI Constant speed control

http://www.impactrm.com/glossary.asp (3 of 11) [5/15/2004 9:23:46 AM] Impact RM Compressed Air Glossary of Terms

d Dalton's law DC Dead end pressure Deairentrainment Degrees Celsius (°C) Degrees Fahrenheit (°F) Degrees Kelvin (°K) Degree Rankine (°R) Degree of intercooling Degree of saturation Deliquescent Deliquescence Delta P Delta T Demand Demand side management (DSM) Demulsibility Density Depth filter Desiccant Design pressure Desorption Dew point Dew point cup Diaphragm Diaphragm compressor Diaphragm cooling Diaphragm routing Differential pressure Differential pressure indicator Diffuser Digital controls Diluent Direct current Directional control valve Dirt holding capacity Disc Discharge piping Discharge pressure Discharge temperature Displacement compressor Displacement of a compressor Disposable filter DOE DOP Double acting compressor Downstream Drag Drain valve Dripleg Drive Dropleg Dry adiabatic lapse rate Dry bulb temperature Dry gas Dry unit (oil free) Dynamic losses Dynamic type compressors Dynamic viscosity (Dynamic) Dual control Duct Durometer Dust cake Dust holding capacity Duty cycle Dry-pipe Darcy's Law Degree Réaumur (°Ré) Droop Dynamic calibration Dynamic range Dynamic pressure

e Effective area Efficiency Efficiency compression Efficiency isothermal Efficiency mechanical Efficiency polytropic Efficiency volumetric Ejector compressor Element Emulsibility Emulsifier Emulsion End cap Energy audit Energy conservation Energy storage Enrichment Enthalpy Entrainment ratios Entropy Environmental contaminant Evaporation Evaporator Exhauster Exothermic Expanders Eductor tube

ee Energy kinetic

http://www.impactrm.com/glossary.asp (4 of 11) [5/15/2004 9:23:46 AM] Impact RM Compressed Air Glossary of Terms

f FAD Fatigued Ferrography Fick's law of diffusion Filter Filter breather Filter coalescing Filter efficiency Filter element Filter head Filter housing Filter inline Filter life test Filter medium Filter oil bath Filter separator Filtration First law of thermodynamics Fixed compression ratio Flange Flash point Flexible mounting Flow Flow control valve Flow diagram Flow meter Flow rate Fluidics Flushing Foot Forced draft fan Fouling Free air (FAD) Friction FRL Frost point Full load Fresh air make-up Fail safe Fail safe oeration Ferrule Fick`s First Law Fick`s Second Law Flow tube FPM FPS Free energy Frequency natural

g Gag Galling Gallon Gas Gas bearings Gas bypass Gas compressor Gas drying Gas laws Gate valve Gauge Gauge pressure Glycol dehydration Governor GPM Grade D breathable compressed air Gravimetric efficiency Guide Gauge pressure transducer Gas booster Gas recievers

h Halocarbon Head adiabatic Header Head polytropic Head pressure Heat capacity Heat exchanger Heatless dryer Heat reactivated dryers Heat recovery High efficiency filtration High volume low pressure Horsepower (HP) Horsepower brake (BHP) Horsepower gas Horsepower ideal Horsepower indicated Horsepower peak Horsepower theoretical Hot gas Hot gas bypass valve Hot start Housing Humidity Humidity specific Humidity relative HVLP HYCO Hydrocarbons Hydrogen chlorofluorocarbons (HCFC) Hygroscopic cells Hermetic Hot gas reflow Hygrometer Hygroscopic Hypercavitation

http://www.impactrm.com/glossary.asp (5 of 11) [5/15/2004 9:23:46 AM] Impact RM Compressed Air Glossary of Terms

Hysteresis

i IBV ICFM I.D. Ideal gas Ideal multi stage compression IGV Immiscible Impeller Inches of water Inches of water gauge Incremental air fee Incremental air requirement Indicated power Indicator card Indicator pressure Induced draft Inducer Inerting

Inert gas Inertia base Inertia forces Influent Ingested contaminants Inlet pressure Inlet temperature Inlet throttle Inline filter Insolubles Instrument air Intake filter Intake filter silencer Intank check valve Intercooler Intercooling Internal energy International Organization for Standardization Irreversible process Isentrop Isentropic compression Isentropic efficiency Isentropic power consumption ISO Isobar Isochor Isotherm Isothermal compression Isothermal efficiency Isothermal power consumption Inspiratory reserve volume Impedance Inert atmosphere Inlet check valve Instrumentation Intensifier Interstage stall Interface

j Jackleg Jack hammer Jet Joule Joule effect Joule Thompson effect Jounce Journal Journal bearing JTPF JTPM

k Kelvin (K) KG/CM²A Kickout type clutch Kilo Kilobar (kb) Kilowatt (kW) Kilowatt hour (kWh) Kinematic viscosity Kinetic energy Knock out kPa K value kW kWh Kilovolt-Amperes (kva) KRISS Kyoto protocol

http://www.impactrm.com/glossary.asp (6 of 11) [5/15/2004 9:23:46 AM] Impact RM Compressed Air Glossary of Terms

l L/sec Labyrinth compressor Lacquer Langelier's index Laser gas lb lb/hr Leak air Leak detector ultrasonic Lift Lift bag Linear actuator Liner Liquefied compressed gas Liquid piston Liquid ring rotary compressor Liquid ring rotary compressor LNG Load Loaded Load factor Load time Lobe Low pressure coat Lubrication Lubricator Lag Line pressure

m M3/min M3/hr Mach number Manifold Man way MAWP Maximum operating pressure Mayonnaise Mechanical efficiency Media Media migration Medium Membrane dryer Mesh size Micromanometer Micron Micron rating Millibar Mineral oil MMCFD Modulating control Modulating unload Modulating unload Moisture separator Moisture trap Molecular sieves Mole sieve Molecular theory Mottling MPCV MSDS Multistage axial compressor Multistage centrifugal compressor Multistage compressor Magnehelic gauge Manometer Manual Reset (Adjustment) Manual Reset (Switch) Maximum compression ratio Mass flow rate Maximum operating temperature

n N cu m/min N cu m/hr Natural frequency N.B. NEC Needle gauge Needle scaler Negative pressure NEMA NFPA Nitrox NL NM³/HR No load Nominal efficiency Nominal filter rating Nominal micron rating Noncondensables Noncooled compressor cylinders Noncorrosive gas Nonlubricated compressor Normal air Nozzle Nozzle (valves) NPT NPTT NTP NEMA-12 NEMA-4 NEMA-7 Newtons 1st and 2nd laws of motion Newtons third law of motion NIST Nominal ratio

http://www.impactrm.com/glossary.asp (7 of 11) [5/15/2004 9:23:46 AM] Impact RM Compressed Air Glossary of Terms

o O.D. OEM Off gas Oil aerosol Oil bath filter Oil free Oil free compressor Oil-less Oil system Operating pressure Operating pressure burst Orifice OSHA Overhung type centrifugal Overpressure accumulation compressor Ohms law On/off controller Orifice plate Outlet check valve

p P1 P2 P3 P4 P5 Package power Palm coupling Particle density Particulate type filter Paving breaker PCM PDP Peak demand Pedestal type centrifugal Perfect intercooling compressor Performance curve Permeability pH Pinion Piston displacement Pitot tube Pleated filter Pneumatic Pneumatic power Pneumatics Pneumatic tools PNEUROP oxidation test (POT) Point of use Pore Positive displacement compressors Potential energy PSI - Pounds per square inch. (099) Pour point Power theoretical Power wheel PPB PPBV PPM Precool Precooler Pre open warn Pressure Pressure absolute Pressure back Pressure cracking Pressure critical Pressure dew point Pressure discharge Pressure drop Pressure gauge Pressure inlet Pressure pot Pressure range Pressure rated Pressure regulating valve Pressure relief device Pressure rise Pressure static Pressure swing dryer Pressure system Pressure total Pressure transfer Pressure velocity Preventive maintenance Process Pseudo critical pressure PSI PSIA PSID PSIG Psychrometry PTFE Pulsation damper Pumping Purge air Purging PSIS P&ID

http://www.impactrm.com/glossary.asp (8 of 11) [5/15/2004 9:23:46 AM] Impact RM Compressed Air Glossary of Terms

q Qci Qca Qcr Quick coupler

r Radial compressor Ram Rebound Receivers Reciprocating compressors Recovery pressure Reduced pressure Reduced temperature Refrigerant Refrigeration dryer Regeneration Regulator Reheaters Relative clearance volume Relative humidity Relative vapor pressure Relief valve Required capacity Reversible process Reynold's number Rings Ring sticking Rock drill ROI Rolling element Rotary actuator Rotary blowers Rotary compressors Rotary sliding vane compressors Rust prevention test Return flow compressor Raw air Rankine or R Rheology Recovery time Room conditions Rule of Thumb - Power 1 Rule of Thumb - Power 2 Rule of Thumb - Power 3 Rule of Thumb - Air intake Rule of Thumb - Cooling Rule of Thumb - Cooling 2 Rule of Thumb - Cooling 3 Rule of Thumb - Receiver Rule of Thumb - Receiver 2 Rule of Thumb - Air line losses 1 Rule of Thumb - Air line losses 2 Rule of Thumb - Air line losses 3 Rule of Thumb - Air line losses 4 Rule of Thumb - Altitude 1 Rule of Thumb - Altitude 2 Rule of Thumb - Distribution piping Rule of Thumb - Filter sizing Rule of Thumb - Temperature Rule of Thumb - Drains Rotor

s SAE Safety valve Safety relief valve Saturated air vapor mixture Saturated vapor pressure Saturation Saturation pressure Scale SCFM Screw compressor SCUBA Sea level Seals Seat Second law of thermodynamics Sequence Set pressure Shaft Shaft input Shaft sleeves Shaft speed irregularity Sheltered set SI Silencer Silica gel Single acting Single stage compressors Single stage centrifugal Siphon feed gun Sleeve compressors Slip Slip RPM Sludge Slusher Snifting valve Sole plate Sonic flow SOP SPC Specialty gases Specific energy requirement Specific fuel consumption

http://www.impactrm.com/glossary.asp (9 of 11) [5/15/2004 9:23:46 AM] Impact RM Compressed Air Glossary of Terms

Specific gravity Specific heat Specific humidity Specific power Specific volume Specific weight Speed Speed of sound Spindle SRM Stability Stack up Stages Standard air Standard cubic foot Standard pressure and temperature Start stop control (SPT) State (SPT) Stem Sterile air Stonewall STP Strainer Stroke total Stroke usable Subheaders Suction pressure Supercompressibility factor Surface filtration Surge Surge limit Swept volume Synthetic gas Synthetic lubricant Swash plate compressor Single-acting pump Single ended pump Single ended gas booster Steady flow Set point Stagnation pressure Static pressure Static calibration Steady state vibration

t T1 T3 Temperature Temperature absolute Temperature discharge Temperature inlet Temperature intake Temperature rise ratio Temperature static Temperature total Theoretical power Thermal compressor Thermal mass Thermodynamics first law of Thermodynamics second law of Thrust balancing device Tilting pad Torr Total package input power Torque Trunk compressor Trunnion Tugger Tundish Two stage compressor Two step control TXV valve Twin cylinder compressor Tidal volume TEMPCO Test gas Thermowell Transitional flow Transmitter Transducer Tank assisted CFM

u UL Ultrasonic leak detector UNC UNF Unit type compressors Unload Unloaded horsepower Utilization factor Uniflow compressor Undershoot Union Unswept volume Undershoot Unloader

http://www.impactrm.com/glossary.asp (10 of 11) [5/15/2004 9:23:46 AM] Impact RM Compressed Air Glossary of Terms

v Vacuum pumps Valves Vane compressor Vane material Vapor Vaporization Vapor pressure Varnish V belt drive Vent loss Venturi Viscosity Viscosity index (VI) Volumetric efficiency Volute Voting alarm Volt-Ampere (VA) Voltmeter

w Warn Water cooled compressors Water solubility Wet bulb temperature Wet gas Wet helical lobe unit Wicking Winch WMW WOG Work Working pressure Warmup Wetted parts

x Xenon

y Y-Cylinder Yoke

z ZDDP Zeolite Zero Zero discharge water Zero adjustments

[ INDEX ] A B C D E F G H I J K L M N O P Q R S T U V W X Y Z [ADD]

Please read our disclaimer and our credits page If you found this interesting, please send us your comments. If we missed some important entry, please use this form to submit it. Proper credit will be given for original and unique entries. By submitting an entry you give up any copyright or other claim to it.

CONTACT-US Compressed Air Management Impact RM Inc. Toll free: (Canada /USA): 1 (800) 463-1385 1051 Avenue Saint Charles, Suite 107 Phone: (450) 424-1385 - Fax: (450) 424-6623 Vaudreuil-Dorion (Quebec) Canada J7V 8P5 Email: [email protected]

http://www.impactrm.com/glossary.asp (11 of 11) [5/15/2004 9:23:46 AM] Cashco Terminology

Cashco Terminology

ACTUATOR: A fluid-powered or electrically powered device that supplies force and motion to a VALVE CLOSURE MEMBER.

AIR SET: Also SUPPLY PRESSURE REGULATOR. A device used to reduce plant air supply to valve POSITIONERS and other control equipment. Common reduced air supply pressures are 20 and 35 psig.

AIR-TO-CLOSE: An increase in air pressure to the ACTUATOR is required to cause the valve to close. This is another way of saying the valve is Fail Open or Normally Open.

AIR-TO-OPEN: An increase in air pressure to the ACTUATOR is required to cause the valve to open. This is another way of saying the valve is FAIL CLOSED or NORMALLY CLOSED.

ANSI: An abbreviation for the American National Standards Institute.

ANTI-CAVITATION TRIM: A special trim used in CONTROL VALVES to stage the pressure drop through the valve, which will either prevent the CAVITATION from occurring or direct the bubbles that are formed to the center of the flow stream away from the valve BODY and TRIM. This is usually accomplished by causing the fluid to travel along a torturous path or through successively smaller orifices or a combination of both.

API: An abbreviation for the American Petroleum Institute.

ASME: An abbreviation for the American Society of Mechanical Engineers.

ASTM: An abbreviation for the American Society for Testing and Materials.

BALANCED TRIM: A trim arrangement that tends to equalize the pressure

above and below the valve plug to minimize the net static and dynamic fluid

flow forces acting along the axis of the stem of a GLOBE VALVE. Some

regulators also use this design, particularly in high pressure service.

http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (1 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology BELLOWS SEAL BONNET: A BONNET which uses a BELLOWS for sealing against leakage around the valve plug stem.

BENCH SET: The proper definition for bench set is the INHERENT DIAPHRAGM PRESSURE RANGE, which is the high and low values of pressure applied to the diaphragm to produce rated valve plug travel with atmospheric pressure in the valve body. This test is often performed on a work bench in the instrument shop prior to placing the valve into service and is thus known as Bench Set.

BODY: The body of the valve is the main pressure boundary. It provides the pipe connecting ends and the fluid flow passageway. It can also support the seating surface and the valve CLOSURE MEMBER.

BONNET: The bonnet or bonnet assembiy is that portion of the valve pressure retaining boundary which may guide the stem and contains the PACKING BOX and STEM SEAL. The bonnet may be integral to the valve body or bolted or screwed. The bonnet, if it is detachable, will generally provide the opening to the valve body cavity for removal and replacement of the internal TRIM. The bonnet is generally the means by which the actuator is connected to the valve body.

BOOSTER: A pneumatic relay that is used to reduce the time lag in pneumatic circuits by reproducing pneumatic signals with high-volume and or high- pressure output. These units may act as volume boosters or as amplifiers. A 1:2 booster will take a 3 to 15 psig input signal and output a 6 to 30 psig signal. It has also been shown that a booster may improve the performance of a control valve by replacing a positioner. It can provide the same stroking speed and can isolate the controller from the large capacitive load of the actuator.

BUBBLE TIGHT: A commonly used term to describe the ability of a control valve or regulator to shut off completely against any pressure on any fluid. Unfortunately, it is completely unrealistic. Control valves are tested to ANSI B16.104 and FCI 70-2-1976 which is the American National Standard for Control Valve Seat Leakage. This standard uses 6 different classifications to describe the valves seat leakage capabilities. The most stringent of these is Class VI which allows a number of bubbles per minute leakage, depending on the port size of the valve. The correct response to the question "Will that valve go "Bubble Tight"? is to say this valve is tested to meet Class VI shutoff requirements.

BUTTERFLY VALVE: A valve with a circular body and a rotary motion disk closure member which is pivotally supported by its stem. Butterfly valves come http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (2 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology

in various styles including eccentric and high-performance valves. Butterfly valves are HIGH RECOVERY valves and thus tend to induce CAVITATION in liquid services at much lower pressure drops and fluid temperatures than the globe style valve. Due to instability problems with the older design butterfly valves, many people will limit the travel of the valve at 60 degrees of rotation on throttling services. This can also help keep the valve out of CAVITATION problems.

CAGE: A hollow cylindrical trim element that is sometimes used as a guide to align the movement of a VALVE PLUG with a SEAT RING. It may also act to retain the seat ring in the valve body. On some types of valves, the cage may contain different shaped openings which act to characterize the flow through the valve. The cage may also act as a NOISE ATTENUATION or ANTI- CAVITATION device.

CAGE GUIDED VALVE: A type of GLOBE STYLE valve trim where the valve plugs with the seat.

CAVITATION: Occurs only in liquid service. In its simplest terms cavitation is the two-stage process of vaporization and condensation of a liquid. Vaporization is simply the boiling of a liquid, which is also known as FLASHING. In a control valve this vaporization takes place because the pressure of the liquid is lowered, instead of the more common occurrence where the temperature is raised. As fluid passes through a valve just downstream of the orifice area, there is an increase in velocity or kinetic energy that is accompanied by a substantial decrease in pressure or potential energy. This occurs in an area called the VENA CONTRACTA. If the pressure in this area falls below that of the vapor pressure of the flowing fluid, vaporization (boiling) occurs. Vapor bubbles then continue downstream where the velocity of the fluid begins to slow and the pressure in the fluid recovers. The vapor bubbles then collapse or implode. Cavitation can cause a Choked Flow condition to occur and can cause mechanical damage to valves and piping.

CHOKED FLOW: Also known as CRITICAL FLOW. This condition exists when at a fixed upstream pressure the flow cannot be further increased by lowering the downstream pressure. This condition can occur in gas, steam, or liquid services. Fluids flow through a valve because of a difference in pressure between the inlet (Pl) and outlet (P2) of the valve. This pressure difference (Delta-P) or pressure drop isessential to moving the fluid. Flow is proportional to the square root of the pressure drop. Which means that the higher the pressure drop is the more fluid can be moved through the valve. If the inlet pressure to a valve remains constant, then the differential pressure can only be increased by lowering the outlet pressure. For gases and steam, which are http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (3 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology compressible fluids, the maximum velocity of the fluid through the valve is limited by the velocity of the propagation of a pressure wave which travels at the speed of sound in the fluid. If the pressure drop is sufficiently high, the velocity in the flow stream at the VENA CONTRACTA will reach the velocity of sound. Further decrease in the outlet pressure will not be felt upstream because the pressure wave can only travel at sonic velocity and the signal will never translate upstream. Choked Flow can also occur in liquids but only if the fluid is in a FLASHING or CAVITATING condition. The vapor bubbles block or choke the flow and prevent the valve from passing more flow by lowering the outlet pressure to increase the pres-sure drop. A good Rule Of Thumb on Gases and Steam service is that if the pressure drop across the valve equals or exceeds one half the absolute inlet pressure, then there is a good chance for a choked flow condition. Example:

P1 100 psig P2 25 psig ______Delta P = 75

P1 (ABS) = 100 + 14.7 or 114.7 1/2 of 114.7 = 57.35 Actual pressure drop = 75 Choked Flow is probable.

The style of valve (that is whether it is a HIGH RECOVERY or a LOW RECOVERY style) will also have an effect on the point at which a choked flow condition will occur.

CLOSURE MEMBER: The movable part of the valve which is positioned in the flow path to modify the rate of flow through the valve. Some of the different types of closure members are the Ball, Disk, Gate, and Plug.

COEFFICIENT FLOW: A constant (Cv) that is used to predict the flow rate through a valve. It is related to the geometry of the valve at a given valve opening. See Cv.

CONTROL VALVE: Also known as the FINAL CONTROL ELEMENT. A power-operated device used to modify the fluid flow rate in a process control system. It usually consists of a BODY or VALVE and an ACTUATOR, which responds to a signal from the controlling system and changes the position of a FLOW CONTROLLING ELEMENT in the valve.

http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (4 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology CONTROL VALVE GAIN: The relationship between valve travel and the flow rate through the valve. It is described by means of a curve on a graph expressed as an INSTALLED OR INHERENT CHARACTERISTIC.

CONTROLLER: A device which tells a CONTROL VALVE what to do. Controllers can be either pneumatic or electronic. There are pressure, temperature, ph, level, differential, and flow controllers. The job of the controller is to sense one of the above variables and compare it to a set point that has been established. The controller then outputs a signal either pneumatic or electronic to the control valve, which then responds so as to bring the process variable to the desired set point.

CRITICAL FLOW: See the definition for CHOKED FLOW.

CV: The VALVE FLOW COEFFICIENT is the number of U.S. gallons per minute of 60 degree F water that will flow through a valve at a specified opening with a pressure drop of 1 psi across the valve.

DELTA-P: Differential Pressure. The inlet pressure (Pl) minus the outlet pressure (P2). Example:

P1 = 100 psig P2 = 25 psig. ______Delta-P = 75

DIAPHRAGM: A flexible pressure-responsive element that transmits force to the diaphragm plate and actuator stem.

DIAPHRAGM ACTUATOR: Is a fluid (usually pneumatic) pressure- operated, spring-opposed diaphragm assembly which positions the valve stem in response to an input signal.

DIAPHRAGM PRESSURE: See Bench Set.

DIAPHRAGM VALVE: A valve with a flexible linear motion CLOSURE MEMBER that is forced into the internal flow passageway of the BODY by the ACTUATOR. Pinch or Clamp valves and Weir-type valves fall into this category.

DIRECT ACTING: This term has several different meanings depending upon

http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (5 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology the device it is describing. A DIRECT-ACTING ACTUATOR is one in which the actuator stem extends with an increase in diaphragm pressure. A DIRECT- ACTING VALVE is one with a PUSH-DOWN-TO-C LOSE plug and seat orientation. A DIRECT-ACTING POSITIONER or a DIRECT-ACTING CONTROLLER outputs an increase in signal in response to an increase in set point.

DIRECT ACTUATOR: Is one in which the actuator stem extends with an increase in diaphragm pressure.

DUAL SEATING: A valve is said to have dual seating when it uses a resilient or composition material such as TFE, Kel-F, or Buna-N, etc. for its primary seal and a metal-to-metal seat as a secondary seal. The idea is that the primary seal will provide tight shut-off Class VI and if it is damaged the secondary seal will backup the primary seal with Class IV shut-off.

DYNAMIC UNBALANCE: The total force produced on the valve plug in any stated open position by the fluid pressure acting upon it. The particular style of valve, i.e. single-ported, double-ported, flow-to-open, flow-to-close, has an effect on the amount of dynamic unbalance.

EFFECTIVE AREA: For a DIAPHRAGM ACTUATOR, the effective area is that part of the diaphragm area that is effective in producing a stem force. Usually the effective area will change as the valve is stroked - being at a maximum at the start and at a minimum at the end of the travel range. Flat sheet diaphragms are most affected by this; while molded diaphragms will improve the actuator performance, and a rolling diaphragm will provide a constant stem force throughout the entire stroke of the valve.

ELECTRIC ACTUATOR: Also known as an Electro-Mechanical Actuator uses an electrically operated motor-driven gear train or screw to position the actuator stem. The actuator may respond to either a digital or analog electrical signal.

END CONNECTION: The configuration provided to make a pressure-tight joint to the pipe carrying the fluid to be controlled. The most common of these connections are threaded, flanged, or welded.

EQUAL PERCENTAGE: A term used to describe a type of valve flow characteristic where for equal increments of valve plug travel the change in flow rate with respect to travel may be expressed as a constant percent of the flow rate at the time of the change. The change in flow rate observed with

http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (6 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology respect to travel will be relatively small when the valve plug is near its seat and relatively high when the valve plug is nearly wide open.

EXTENSION BONNET: A bonnet with a packing box that is extended above the body to bonnet connection so as to maintain the temperature of the packing above (cryogenic service) or below (high-temp service) the temperature of the process fluid. The length of the extension depends on the amount of temperature differential that exists between the process fluid and the packing design temperature.

FACE-TO-FACE: Is the distance between the face of the inlet opening and the face of the outlet opening of a valve or fitting. These dimensions are governed by ANSI/ISA specifications.

The following Uniform Face-to Face Dimensions apply.

SPECIFICATION VALVE TYPE

ANSI/ISA S75.03 INTEGRAL FLANGED GLOBE STYLE CONTROL VALVES ANSI/ISA S75.04 FLANGELESS CONTROL VALVES ANSUISA S75.20 SEPARABLE FLANGE GLOBE STYLE CONTROL VALVES

FAIL-CLOSED: Or NORMALLY CLOSED. Another way of describing an AIR-TO-OPEN actuator. Approximately 80% of all spring return diaphragm operators in the field are of this construction.

FAIL-IN-PLACE: A term used to describe the ability of an actuator to stay at the same percent of travel it was in when it lost its air supply. On SPRING RETURN ACTUATORS this is accomplished by means of a LOCK-UP VALVE. On PISTON ACTUATORS a series of compressed air cylinders must be employed.

FAIL-OPEN: Or NORMALLY OPEN. Another way of describing an AIR-TO- CLOSE actuator.

FAIL-SAFE: A term used to describe the desired failure position of a control valve. It could FAIL-CLOSED, FAIL-OPEN, or FAIL-IN-PLACE. For a spring-return operator to fail-in-place usually requires the use of a lock-up valve.

http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (7 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology FEEDBACK SIGNAL: The return signal that results from a measurement of the directly controlled variable. An example would be where a control valve is equipped with a positioner. The return signal is usually a mechanical indication of valve plug stem position which is fed back into the positioner.

F1: Or PRESSURE RECOVERY FACTOR. A number used to describe the ratio between the pressure recovery after the VENA CONTRACTA and the pressure drop at the vena contracta. It is a measure of the amount of pressure recovered between the vena contracta and the valve outlet. Some manufacturers use the therm Km to describe the pressure recovery factor. This number will be high (0.9) for a GLOBE STYLE VALVE with a torturous follow path and lower (0.8 to 0.6) for a ROTARY STYLE VALVE with a streamlined flow path. On most rotary products the F1 factor will vary with the degree of opening of the VALVE CLOSURE MEMBER. Note! F1 does not equal Km.

FLANGELESS: A valve that does not have integral line flanges. This type of valve is sometimes referred to as a Wafer Style valve. The valve is installed by bolting it between the companion flanges with a set of bolts or studs called line bolting. Care should be taken that strain-hardened bolts and nuts are used in lieu of all-thread, which can stretch when subjected to tempera-ture cycling.

FLANGELESS BODY: See FLANGELESS for a definition. This type of valve is very economical from a manufacturing and stocking standpoint because a valve that is rated as a 600# ANSI valve can also be used between 150# and 300# ANSI flanges thus eliminating the need to manufacture three different valve bodies or stock three different valve bodies. The down side is that valves with flangeless bodies are not acceptable in certain applications - particularly in refinery processes.

FLASHING: Is the boiling or vaporizing of a liquid. See the definition of CAVITATION. When the vapor pressure downstream of a control valve is less than the upsteam vapor pressure, part of the liquid changes to a vapor and remains as a vapor unless the downstream pressure recovers significantly, in which case CAVITATION occurs. Flashing will normally cause a CHOKED FLOW condition to occur. In addition the vapor bubbles can also cause mechanical damage to the valve and piping system.

FLOW CHARACTERISTIC: The relationship between valve capacity and valve travel. It is usually expressed graphically in the form of a curve. CONTROL VALVES have two types of characteristics INHERENT and INSTALLED. The INHERENT characteristic is derived from testing the valve with water as the fluid and a constant pressure drop across the valve. When

http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (8 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology valves are installed into a system with pumps, pipes, and fittings, the pressure dropped across the valve will vary with the travel. When the actual flow in a system is plotted against valve opening, the curve is known as the INSTALLED flow characteristic. Valves can be characterized by shaping the plugs, orifices, or cages to produce a particular curve. Valves are characterized in order to try to alter the valve gain.

Valve gain is the flow change divided by the control signal change. This is done in an effort to compensate for nonlinearities in the control loop.

FLOW COEFFICIENT: See the definition for Cv.

GAIN: The relationship of input to output. If the full range of the input is equal to the full range of the output, then the gain is 1. Gain is another way to describe the sensitivity of a device.

GLOBE VALVE: A valve with a linear motion, push-pull stem, whose one or more ports and body are distinguished by a globular shaped cavity around the port region. This type of valve is characterized by a torturous flow path and is also referred to as a LOW RECOVERY VALVE because some of the energy in the flow stream is dissipated; and the inlet pressure will not recover to the extent that it would in a more streamlined HIGH RECOVERY VALVE.

HANDWHEEL: A manual override device used to stroke a valve or limit its travel. The handwheel is sometimes referred to as a hand jack. It may be top mounted, side mounted, in-yoke mounted or shaft mounted and declutchable.

HARD FACING: A material that is harder than the surface to which it is applied. It is normally used to resist fluid erosion or to reduce the chance of galling between moving parts. Hard facing may be applied by fusion welding, diffusion, or spray coating the material. Alloy #6 or Stellite is a common material used for this purpose.

HARDNESS: A property of metals that is discussed frequently when speaking of various component parts used in valve construction, particularly valve trim. There are two hardness scales which are commonly used, Rockwell & Brinell.

HARDNESS COMPARISON ROCKWELL BRINELL

http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (9 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology

316 SST 76B 137 17-4 PH 34-38C 352 Hardened Inconel X-750 38-42C 401 #6 Stellite (Alloy 6) 40-44C 415 Chrome Plating 59-67C 725 Note that 316 SST is on the Rockwell B scale which means it is a much softer material than the others shown.

HIGH RECOVERY VALVE: A valve design that dissipates relatively little flow stream energy due to streamlined internal contours and minimal flow turbulence. Therefore, pressure down stream of the valve VENA CONTRACTA recovers to a high percentage of its inlet value. These types of valves are identifiable by their straight-th rough flow paths. Examples are most rotary control valves, such as the eccentric plug, butterfly, and ball valve.

HYSTERESIS: The difference between up-scale and down-scale results in instrument response when subjected to the same input approached from the opposite direction. Example: A control valve has a stroke of 1.0 inch and we give the valve a 9 psig signal. The valve travels 0.500 of an inch. We then give the valve a 12 psig signal, and the valve travels to 0.750 of an inch. When the valve is then given a 9 psig signal, the stroke is measured at 0.501. That represents hysteresis. Hysteresis can be caused by a multitude of variables, packing friction, loose linkage, pressure drop, etc. If someone asks you what the hysteresis of your control valve is, it is a bum question because hysteresis is more aptly applied to an instrument than to a control valve. There are simply too many variables in the valve and the system to answer the question properly. The control valve only responds to the controller signal and will move to a position to satisfy the controller - thus negating the effects of hysteresis.

INCIPIENT CAVITATION: Is a term used to describe the early stages of CAVITATION. At this point the bubbles are small, and the noise is more of a hiss, like the sound of frying bacon. There is normally no mechanical damage associated with incipient cavitation although it could have an effect on the corrosive properties of some fluids.

INHERENT DIAPHRAGM PRESSURE: The high and low values of pressure applied to the diaphragm to produce rated valve plug travel with atmospheric pressure in the valve body. This is more commonly referred to as

http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (10 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology BENCH SET.

INHERENT FLOW CHARACTERISTIC: It is the relationship between valve capacity and valve travel and is usually expressed graphically. It is derived from testing a valve with water as the fluid and with a constant pressure drop across the valve. The most common types of inherent flow characteristics are LINEAR, EQUAL PERCENTAGE, MODIFIED PARABOLIC, and QUICK OPENING.

INSTALLED DIAPHRAGM PRESSURE: The high and low values of pressure applied to the diaphragm to produce rated travel with stated conditions in the valve body. The "stated conditions" referred to here mean the actual pressure drops at operating conditions. Example: A control valve may have an INHERENT DIAPHRAGM PRESSURE or BENCH SET of 8 to 15 psig. But when subjected to a 600 psig. inlet pressure, it may start to open at 3 psig. and be full open at 15 psig. It is because of the forces acting on the valve plug and the direction of flow through the valve (FLOW-TO-OPEN or FLOW-TO- CLOSE) that the installed diaphragm pressure will differ from the inherent diaphragm pressure.

INSTALLED FLOW CHARACTERISTIC: The flow characteristic when the pressure drop across the valve varies with flow and related conditions in the system in which the valve is installed. The purpose of characterizing a control valve is to help compensate for nonlinearities in the control loop.

INSTRUMENT PRESSURE: The output pressure from an automatic controller that is used to operate a control valve. It is the input signal to the valve.

INTEGRAL SEAT: The flow control orifice and seat that is an integral part of the valve body or cage. The seat is machined directly out of the valve body and is normally not replaceable without replacing the body itself - although some can be repaired by welding and remachining.

INTEGRAL FLANGE: A valve body whose flange connection is an integral or cast part of the body. Valves with integral flanges were traditionally known to have the ANSI short FACE-TO-FACE dimension ANSI/ISA S75.03. However many manufacturers now produce valve bodies with both integral and SEPARABLE FLANGES that will meet both the ANSI short and long face-to- face dimensions.

I/P: An abbreviation for current-to-pneumatic signal conversion. This term is

http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (11 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology commonly used to describe a type of transducer that converts an electric (4-20 m.a) input signal to a pneumatic (3-15 psig.) output signal.

LANTERN RING: A rigid spacer used in the packing with packing above and below it. The lantern ring is used to allow lubrication to the packing or allow access to a leak off connection. On some of the new fugitive emission packing systems, it also acts as a stem guide.

LAPPED-IN: A term that describes a procedure for reducing the leakage rate on metal-to-metal seated valves and regulators. The plug and seat are lapped together with the aid of an abrasive compound in an effort to establish a better seating surface than would normally be achieved by means of machining.

LEAKAGE CLASSIFICATION: A term used to describe certain standardized testing procedures for CONTROL VALVES with a FLOW COEFFICIENT greater then 0. 1 (Cv). These procedures are outlined in ANSI Standard d B16.104-1976, which gives specific tests and tolerances for six seat leakage classifications. It should be remembered that these tests are used to establish uniform acceptance standards for manufacturing quality and are not meant to be used to estimate leakage under actual working conditions. Nor should anyone expect these leakage rates to be maintained after a valve is placed in service. There is no standard test for SELF-CONTAINED REGULATORS at this time. Note! You will see many instances where regulators are specified using the above criteria.

LEAK-OFF: A term used to describe a threaded connection located on the BONNET of a valve that allows for the detection of leakage of the process fluid past the packing area.

LINEAR FLOW CHARACTERISTIC: A characteristic where flow capacity or (Cv) increases linearly with valve travel. Flow is directly proportional to valve travel. This is the preferred valve characteristic for a control valve that is being used with a distributive control system (DCS) or programmable logic controller (PLC).

LINEAR VALVE: Another name for a GLOBE VALVE. It refers to the linear or straight-line movement of the plug and stem.

LIQUID PRESSURE RECOVERY: See (F1).

LOADING PRESSURE: The pressure used to position a pneumatic actuator. It is the pressure that is actually applied to the actuator diaphragm or piston. It http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (12 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology can be the INSTRUMENT PRESSURE if a valve positioner is not used or is bypassed.

LOCK-UP VALVE: A special type of regulator that is installed between the valve POSITIONER and the valve ACTUATOR, where it senses the supply air pressure. If that pressure falls below a certain level, it locks or traps the air loaded into the actuator causing the valve to FAIL-IN-PLACE.

LOW RECOVERY VALVE: A valve design that dissipates a considerable amount of flow stream energy due to turbulence created by the contours of the flow path. Consequently, pressure downstream of the valve VENA CONTRACTA recovers to a lesser percentage of its inlet value than a valve with a more streamlined flow path. The conventional GLOBE STYLE control valve is in this category.

MODIFIED PARABOLIC: A FLOW CHARACTERISTIC that lies somewhere between LINEAR and EQUAL PERCENTAGE. It provides fine throttling at low flow capacity and an approximately linear characteristic at higher flow capacities.

NORMALLY CLOSED: See AIR-TO-OPEN.

NORMALLY OPEN: See AIR-TO-CLOSE.

P1: Is used to designate Inlet Pressure.

P2: Is used to designate Outlet Pressure.

PACKING: A sealing system that normally consists of a deformable material such as TFE, graphite, asbestos, etc. It is usually in the form of solid or split rings contained in a PACKING BOX that are compressed so as to provide an effective pressure seal.

PACKING BOX: The chamber located in the BONNET which surrounds the stem and contains the PACKING and other stem-sealing components.

PACKING FOLLOWER: A part that transfers a mechanical load to the PACKING from the packing flange or nut.

PISTON ACTUATOR: A fluid-powered, normally pneumatic device in which the fluid acts upon a movable cylindrical member, the piston, to provide linear motion to the actuator stem. These units are spring or air opposed and

http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (13 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology operate at higher supply pressures than a SPRING RETURN ACTUATOR.

PLUG: See CLOSURE MEMBER.

PORT-GUIDED: A valve plug that fits inside the seat ring, which acts as a guide bushing. Examples: Splined Plug, Hollow Skirt, and the Feather-Guide Plug.

POSITION SWITCH: A switch that is linked to the valve stem to detect a single, preset valve stem position. Example: Full open or full closed. The switch may be pneumatic, hydraulic, or electric.

POSITION TRANSMITTER: A device that is mechanically connected to the valve stem and will generate and transmit either a pneumatic or electric signal that represents the valve stem position.

POSITIONER: A device used to position a valve with regard to a signal. The positioner compares the input signal with a mechanical feed back link from the actuator. It then produces the force necessary to move the actuator output until the mechanical output position feedback corresponds with the pneumatic signal value. Positioners can also be used to modify the action of the valve (reverse acting positioner), alter the stroke or controller input signal (split range positioner), increase the pressure to the valve actuator (amplifying positioner), or alter the control valve FLOW CHARACTERISTIC (characterized positioner).

POST GUIDE: A guiding system where the valve stem is larger in the area that comes into contact with the guide busings than in the adjacent stem area.

PUSH-DOWN-TO-C LOSE: A term used to describe a LINEAR or GLOBE STYLE valve that uses a DIRECT ACTING plug and stem arrangement. The plug is located above the seat ring. When the plug is pushed down, the plug contacts the seat, and the valve closes. Note! Most control valves are of this type.

PUSH-DOWN-TO-OPEN: A term used to describe a LINEAR or GLOBE STYLE valve that uses a REVERSE ACTION plug and stem arrangement. The plug is located below the seat ring. When the plug is pushed down, the plug moves away from the seat, and the valve opens.

PRESSURE RECOVERY FACTOR: See (F1).

http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (14 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology QUICK OPENING: A FLOW CHARACTERISTIC that provides maximum change in flow rate at low travels. The curve is basically linear through the first 40% of travel. It then flattens out indicating little increase in flow rate as travel approaches the wide open position. This decrease occurs when the valve plug travel equals the flow area of the port. This normally happens when the valve characteristics is used for on/off control.

RANGEABILITY: The range over which a control valve can control. It is the ratio of the maximum to minimum controllable FLOW COEFFICIENTS. This is also called TURNDOWN although technically it is not the same thing. There are two types of rangeability - inherent and installed. Inherent rangeability is a property of the valve alone and may be defined as the range of flow coefficients between which the gain of the valve does not deviate from a specified gain by some stated tolerance limit. Installed rangeability is the range within which the deviation from a desired INSTALLED FLOW CHARACTERISTIC does not exceed some stated tolerance limit.

REDUCED TRIM: Is an undersized orifice. Reduced or restricted capacity trim is used for several reasons. (1) It adapts a valve large enough to handle increased future flow requirement with trim capacity properly sized for present needs. (2) A valve with adequate structural strength can be selected and still retain reasonable travel vs. capacity relationships. (3) A valve with a large body using restricted trim can be used to reduce inlet and outlet fluid velocities. (4) It can eliminate the need for pipe reducers. (5) Errors in over sizing can be corrected by use of restricted capacity trim.

REVERSE ACTING: This term has several deferent meanings depending upon the device it is describing. A REVERSE-ACTING ACTUATOR is one in which the actuator stem retracts with an increase in diaphragm pressure. A REVERSE-ACTING VALVE is one with a PUSH-DOWN-TO-OPEN plug and seat orientation. A REVERSE-ACTING POSITIONER or a REVERSE- ACTING CONTROLLER outputs a decrease in signal in response to an increase in set point.

REVERSE FLOW: Flow of fluid in the opposite direction from that normally considered the standard direction. Some ROTARY VALVES are considered to be bi-directional although working pressure drop capabilities may be lower and leakage rates may be higher in reverse flow.

ROTARY VALVE: A valve style in which the FLOW CLOSURE MEMBER is rotated in the flow stream to modify the amount of fluid passing through the valve.

http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (15 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology SEAT LOAD: The contact force between the seat and the valve plug. When an actuator is selected for a given control valve, it must be able to generate enough force to overcome static, stem, and dynamic unbalance with an allowance made for seat load.

SEAT RING: A part of the flow passageway that is used in conjuction with the CLOSURE MEMBER to modify the rate of flow through the valve.

SELF-CONTAINED REGULATOR: A valve with a positioning actuator using a self-generated power signal for moving the closure member relative to the valve port or ports in response and in proportion to the changes in energy of the controlled variable. The force necessary to position the CLOSURE MEMBER is derived from the fluid flowing through the valve.

SEPARABLE FLANGE: Also known as a SLIP-ON FLANGE. A flange that fits over a valve body flow connection. It is generally held in place by means of a retaining ring. This style of flange connection conforms to ANSI/ISA 275.20 and allows for the use of different body and flange materials. Example: A valve with a stainless steel construction could use carbon steel flanges. This type of valve is very popular in the chemical and petro-chemical plants because it allows the use of exotic body materials and low cost flanges.

SOFT SEATED: A term used to describe valve trim with an elastomeric or plastic material used either in the VALVE PLUG or SEAT RING to provide tight shutoff with a minimal amount of actuator force. A soft seated valve will usually provide CLASS VI seat leakage capability.

SPLIT BODY: A valve whose body is split. This design allows for easy plug and seat removal. Split-bodied valves are made in both the straight-through and angle versions. The Masoneilan 2600 or ANNIN is an example of a split body valve.

SPRING RATE: A term usually applied to SELF-CONTAINED REGULATORS describing the range of set point adjustment available for a particular range spring.

STATIC UNBALANCE: The net force produced on the valve stem by the fluid pressure acting on the CLOSURE MEMBER and STEM within the pressure retaining boundary. The closure member is at a stated opening with a stated flow condition. This is one of the forces an actuator must overcome.

STELLITE: Also called #6 Stellite or Alloy 6. A material used in valve trim

http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (16 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology known for its hardness, wear and corrosion resistance. Stellite is available as a casting, barstock material and may be applied to a softer material such as 316 stainless steel by means of spray coating or welding.

STEM: The VALVE PLUG STEM is a rod extending through the bonnet assembly to permit positioning of the plug or CLOSURE MEMBER. The ACTUATOR STEM is a rod or shaft which connects to the valve stem and transmits motion or force from the actuator to the valve.

STEM GUIDE: A guide bushing closely fitted to the valve stem and aligned with the seat. Good stem guiding is essential to minimizing packing leakage.

SUPPLY PRESSURE: The pressure at the supply port of a device such as a controller, positioner, or transducer. Common values of control valve supply pressures are 20 psig. for a 3-15 psig. output and 35 psig. for a 6-30 psig. output.

STROKE: See TRAVEL.

THROTTLING: Modulating control as opposed to ON/OFF control.

TRANSDUCER: An element or device which receives information in the form of one quantity and coverts it to information in the form of the same or another quantity. (See I/P)

TRAVEL: The distance the plug or stem moves in order to go from a full- closed to a full-open position. Also called STROKE.

TRIM: Includes all the parts that are in flowing contact with the process fluid except the body, BONNET, and body flanges and gaskets. The plug, seats, stem, guides, bushings, and cage are some of the parts included in the term trim.

TRUNNION MOUNTING: A style of mounting the disc or ball on the valve shaft or stub shaft with two bushings diametrically opposed.

TURNDOWN: A term used to describe the ratio between the minimum and maximum flow conditions seen in a particular system. Example: If the minimum flow were 10 G.P.M. and the maximum flow were 100 G.P.M. the turndown would be 10:1. This term is sometimes incorrectly applied to valves. See RANGEABILITY.

http://www.maintenanceresources.com/ReferenceLibrary/ControlValves/CashcoTerminologyPg1.htm (17 of 18) [5/15/2004 9:24:21 AM] Cashco Terminology VALVE: A device which dispenses, dissipates, or distributes energy in a system.

VALVE BODY: See BODY.

VALVE FLOW COEFFICIENT: See Cv.

VALVE PLUG: See CLOSURE MEMBER.

VENA CONTRACTA: The location where cross-sectional area of the flow stream is at its minimum size, where fluid velocity is at its highest level, and where fluid pressure is at its lowest level. The vena contracta normally occurs just downstream of the actual physical restriction in a control valve.

Control Valve Concepts / Actuator Operating Modes / Positioners / Positioner and Controller Operating Modes / Flow Characteristics / Seat Leakage / Packing / Helpful Hints / Advanced Topics

TWI Press can be reached by

Phone: 812.232.0753

Fax: 812.232.3978 E-Mail: [email protected] Via Mail: 120 South 7th Street Terre Haute, IN 47807

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News

Home Laboratory WELCOME TO FMECA Expert System Franchising Products Contact Us FMECA is an acronym for Failure Modes and Effects Criticality Analysis. Its goal is to assist in FAQ structuring maintenance management procedures by systematically considering each failure mode within a complex electrical or mechanical system. The result of performing FMECA is a useful knowledge base which leads to optimal preventive, predictive, and proactive maintenance strategies. Using the FMECA tools provided by PMC's web site, you use the knowledge and experience of your own maintenance and operating personnel to systematically catalogue the failure modes and effects associated with each component part of a system. This accumulated information is assembled and fed back in a variety of forms including diagnostic predictive maintenance reports, which highlight those design, maintenance, operational, and process efforts which will be of highest economic and safety benefit to your company.

FMECA has been developed by NASA, and several useful databases of failure rates and failure modes have been compiled by the Reliability Analysis Center (RAC), a U.S. Department of Defense Information Analysis Center. FMECA includes data obtained under license from the RAC: the information here has been summarized from Failure Mode, Effects, and Criticality Analysis (FMECA) Report No. F30602-91-C-0002 with the permission of the RAC.

● FMECA conforms to and is based on MIL-STD-1629. ● FMECA uses powerful Oracle database technology. ● PMC’s FMECA system is designed as a multilingual application. The client is free to use the interface in the language of his choice. Once he has translated a phrase or part description from one of the common Oracle database tables such as the parts dictionary, that translation is available, from then on, to all users.

For additional information see also...

● Definition of FMECA terms

● Why use FMECA

● FMECA - Mode of Operation

● 5 steps to FMECA and Data Requirements

● Performing a FMEA - Failure Modes and Effects Analysis

● Training and Support

● JOAP Paper - FMECA on the Web

http://packers.pmaint.com/fmeca.htm (1 of 3) [5/15/2004 9:24:33 AM] Predictive Maintenance Corporation

Why use FMECA:

● FMECA has been proven to reduce the costs of maintenance by 30%. ● FMECA makes maintenance a well controlled and structured science. ● FMECA increases effectiveness, reliability and competitiveness for world class success. ● FMECA has been adopted successfully by most military and successful manufacturing organizations

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FMECA - Mode of Operation:

FMECA is an application based on synergy and cooperation.

FMECA utilizes the full knowledge and experience of your maintenance and operational personnel to systematically catalogue the failure modes and effects of each component part of a mechanical or electrical system.

This accumulated information is automatically assembled and fed back in a variety of forms which highlight those design, maintenance, operational, and process modifications and efforts which will be of highest economic and safety benefit to your company.

The result will be a powerful knowledge base that will help you reduce costs and increase reliability.

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5 steps to FMECA and Data Requirements:

These are the 5 steps you will follow in the PMC FMECA system.

1. Define system functions 2. Define modes of operation 3. Develop reliability models 4. Define failure mode effects on higher levels 5. Define severity and frequency of the failure modes

You need:

● A knowledge of FMECA terms

● A complete theory or knowledge of the system ● Schematics ● Bill of Materials/Parts list

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Performing a FMEA - Failure Modes and Effects Analysis:

1. Identify each part in the system by entering it into the PMC FMECA Web Interface. 2. Identify the potential failure modes, their causes, and their effects. You will not have to do this all at once. You can enter what you know, produce hardcopy of your progress, discuss it with your team, and improve the analysis in an iterative approach. 3. Because maintenance is dynamic so must be your FMECA. It must be continually used and updated to provide an effective management tool in the battle for reliability and cost reduction. 4. When systems fail, the failures must be analyzed systematically in the context of FMECA, and the FMECA database must be verified, corrected, and improved in a never ending feedback loop. By providing FMECA with such essential information it will reward you with deep insight into your maintenance tasks.

At this point you will have generated some illuminating reports which allow you to look at the system in ways you haven't yet seen.

So far you have done a FMEA (a FMECA without the Criticality Analysis). The information derived from the FMEA will be useful to you.

It will include:

● a list of hazard risks to be eliminated or reduced ● a list of critical single point failures ● a list of undetectable failures

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Training and Support:

● PMC retains full time system engineers who continually improve the interface so that all of its clients' growing requests are met. ● PMC provides direct assistance in getting you started with FMECA ● PMC conducts seminars and training sessions on FMECA.

Agents who wish to train their clientele on FMECA should communicate with us

Incorporated in Canada in 1984. ISO 9002 certified.

[ Home ] [ Reports ] [ FMECA ] [ TriboLogik™ ] [ Franchising ] [ Laboratory ] [ Products ] [ Contact us! ] [ FAQ ]

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http://web.wt.net/wt404.htm [5/15/2004 9:24:39 AM] MOXIE INTERNATIONAL CONCRETE ADMIXTURES / CONCRETE ...D CONCRETE WATERPROOFERS GLOSSARY OF CONCRETE TERMS

We manufacture concrete admixtures, penetrating concrete sealers, penetrating concrete floor sealers, flooring sealers, concrete waterproofers, brick sealers, block sealers, stucco sealers, plaster waterproofers, shotcrete waterproofers, gunite waterproofers, mortar sealers, concrete cleaners, and concrete repair products.

PRODUCTS HOME TABLE OF CONTENTS

BASIC TUTORIAL ON FREE SERVICES HOW TO ORDER CONCRETE TRANSLATE THIS WEB SITE

Introduction

The people involved in the cement or concrete industries, either in its manufacture, use, or application is so broad that the information contained should be understood by everyone. Whether the reader is an architect, engineer, contractor, worker, supplier of materials, or any one of the many other people involved in the concrete industry, these definitions have been designed to be as clear, basic, and as informative as possible. It is not the intent of this glossary to cover every term in every classification, but those which are most used or misused, or abused.

AAC - Autoclaved Aerated Concrete Exceptionally lightweight precast

http://www.moxie-intl.com/glossary.htm (1 of 31) [5/15/2004 9:25:31 AM] MOXIE INTERNATIONAL CONCRETE ADMIXTURES / CONCRETE ...D CONCRETE WATERPROOFERS GLOSSARY OF CONCRETE TERMS concrete with high thermal qualities and fire resistence. Suitable for cutting with ordinary hand tools. Mix design is composed of portland cement, sand or siliceous material, lime, gypsum, finely powdered aluminum, and water. Initial mix is a combination of portland cement, sand, lime and gypsum to produce a slurry. Finely powdered aluminum mixed into a paste is added prior to placement into large, rail-like forms. The finely powdered aluminum reacts with the alkaline components of the cement and lime to produce hydrogen gas, which increases the volume approximately five times producing a uniformly, dispersed cellular structure. Units are cut to required shape. Units are placed in an autoclave, an enclosed pressurized chamber, and steam cured at 3500 F. Approximately 80% of the ultimate volume consists of air voids.

Abrasion Resistance Resistance of a surface of being worn away by friction or rubbing process.

Absolute Volume The volume of an ingredient in its solid state, without voids between individual pieces or particles, in the case of fluids, the cubic content occupied. In concrete, the actual volume occupied by the different ingredients determined by dividing the weight of each ingredient pounds, by ifs specific gravity, times the weight of one cubic foot of water in pounds. Example: Absolute Volume of one sack of cement equals: 94 ÷ (3.15X62.4) = 0.478 cubic feet

Absorbed Moisture Moisture which is mechanically held in a material. In aggregates, that water which is not available to become part of the mixing water is designated "absorbed" water.

Absorption The process by which water is absorbed. The amount of water absorbed under specific conditions, usually expressed as percentage of the dry weight of the material.

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Accelerator An admixture which, when added to concrete, mortar, or grout, increases the rate of hydration of the hydraulic cement, shortens the time of set and increases the rate of hardening or strength development,

Adiabatic Curing The maintenance of ambient conditions during the setting and hardening of concrete so that heat is neither lost nor gained from the surroundings of the concrete.

Admixture A material other than water, aggregates, and portland cement that is used as an ingredient of concrete, and is added to the batch immediately before or during the mixing operation.

Adsorption Water Water held on surfaces in a material by either physical and/or chemical forces.

Air Content The amount of entrained or entrapped air in concrete or mortar, exclusive of pore space in aggregate particles, usually expressed as a percentage of total volume of concrete or mortar.

Air Entraining Agent An addition for hydraulic cement, or an admixture for concrete or mortar which entrains air in the form of minute bubbles in the concrete or mortar during mixing.

Alkali-Aggregate Reaction Older terminology for Alkali-Silica Reactivity (ASR).

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ASR - Alkali-Silica Reactivity The reaction of aggregates, which contain some form of silica or carbonates with sodium oxides or potassium oxides in cement, particularly in warm, moist climates or environments, causing expansion, cracking or popouts in concrete.

Aluminous Cement A hydraulic cement in which the principal constituents are calcium aluminates, instead of calcium silicates which comprise the major ingredients of portland cement. (See calcium aluminate cement)

Autoclave A chamber in which an environment of steam and high pressure is produced. Used in curing of concrete products and in the testing of hydraulic cement for soundness.

Bag (of cement) (See Sack)

Barrel (of cement) A unit of weight for cement: 376 Ibs net, equivalent to 4 US bags of portland cement. The designation presently used is tons of cement.

Blaine Fineness The fineness of granular materials such as cement and pozzolan, expressed as total surface area in square centimeters per gram, determined by the Blaine air-permeability apparatus and procedure.

Blast Furnace Slag A non-metallic waste product developed in the manufacture of pig iron, consisting basically of a mixture of lime, silica and alumina, the same oxides that make up portland cement, but not in the same proportions or forms.

http://www.moxie-intl.com/glossary.htm (4 of 31) [5/15/2004 9:25:31 AM] MOXIE INTERNATIONAL CONCRETE ADMIXTURES / CONCRETE ...D CONCRETE WATERPROOFERS GLOSSARY OF CONCRETE TERMS It is used both in the manufacture of portland blast furnace slag cement and as an aggregate for lightweight concrete.

Bleeding, Bleed Water A form of segregation in which some of the water in a mix tends to rise to the surface of freshly placed concrete. Known also as water gain.

Bond Adhesion of concrete or mortar to reinforcement, or to other surfaces. The adhesion of cement paste to aggregate.

Bush-hammer A tool having a serrated face, as rows of pyramidal points, used to develop an architectural finish for concrete surfaces.

Calcareous Containing calcium carbonate or, less generally, containing the element calcium.

Calcine To alter composition or physical state by heating to a specific temperature for a specific length of time.

Calcium Aluminate Cement The product obtained by pulverizing clinker consisting essentially of hydraulic calcium aluminates resulting from fusing or sintering a suitable proportioned mixture of aluminous and calcareous materials.

Capillarity A wick-like action whereby a liquid will migrate vertically through material, in a upward direction; as oil in a lamp travels upward through the wick,

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Capillary Space In cement paste, any space not occupied by anhydrous cement or cement gel. Air bubbles, whether entrained or entrapped, are not considered as part of the cement paste.

Carbonation 1) Reaction between the products of portland cement (soluble calcium hydroxides), water and carbon dioxide to produce insoluble calcium carbonate (efflorescence). 2) Soft white, chalky surface dusting of freshly placed, unhardened concrete caused by carbon dioxide from unvented heaters or gasoline powered equipment in an enclosed space. 3) Carbonated, dense, impermeable to absorption, top layer of the surface of concrete caused by surface reaction to carbon dioxide. This carbonated layer becomes denser and deeper over a period of time. 4) Reaction with carbon dioxide which produces a slight shrinkage in concrete. Improves chemical stability. Concrete masonry units during manufacturing may be deliberately exposed to carbon dioxide after reaching 80% strength to induce carbonation shrinkage to make the units more dimensionally stable. Future drying shrinkage is reduced by as much as 30%.

Cellular Concrete A lightweight product consisting of portland cement, cement- pozzolan, cement sand, lime-pozzolan, or lime-sand pastes, or pastes containing blends of these ingredients and having a homogenous void or cell structure, attained with gas forming chemicals or foaming agents. For cellular concretes, containing binder ingredients other than or in addition to portland cement, autoclave curing is usually employed.

Cement, Portland (ASTM C150) A powdery substance made by burning, at a high temperature, a mixture of clay and limestone producing lumps called “clinkers” which are ground into a fine powder consisting of hydraulic calcium silicates. For non-portland cements, see aluminous cement.

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Cement Content A quantity of cement contained in a unit volume of concrete or mortar, ordinarily expressed as pounds, barrels, or bags per cubic yard.

Cement Gel The colloidal gel (glue like) material that makes up the major portion of the porous mass of which hydrated cement paste is composed.

Cementitious Having cement-like, cementing, or bonding type properties. Material or substance producing bonding properties or cement-like materials.

Chair(s) In concrete formwork, the support for the reinforcing steel.

Change of State The process whereby liquid is heated to the point of evaporation changing the liquid into a gas the condensation of a gas on a cooler surface returning it from gaseous to liquid form.

Coarse Aggregate Naturally occurring, processed or manufactured, inorganic particles in prescribed gradation or size range, the smallest size of which will be retained on the No. 4 (4.76 mm) sieve.

Coefficient of Thermal Expansion Change in unit length per degree change of temperature.

Cold Joint A visible lineation which forms when the placement of concrete is

http://www.moxie-intl.com/glossary.htm (7 of 31) [5/15/2004 9:25:31 AM] MOXIE INTERNATIONAL CONCRETE ADMIXTURES / CONCRETE ...D CONCRETE WATERPROOFERS GLOSSARY OF CONCRETE TERMS delayed. The concrete in place hardens prior to the next placement of concrete against it.

Colloidal A gel-like mass which does not allow the transfer of ions

Compressive Strength The measured resistance of a concrete or mortar specimen to axial loading expressed as pounds per square inch {psi) of cross- sectional area. The maximum compressive stress which material, portland cement, concrete, or grout is capable of sustaining.

Concrete A composite material which consists essentially of a binding medium, within which are embedded particles or fragments of a relative inert filler in portland cement concrete, the binder is a mixture of portland cement, possibly additional cementitious materials such as fly ash and water; the filler may be any of a wide variety of natural or artificial, fine and coarse aggregates; and in some instances, an admixture.

Condensation When a moisture laden gas comes in contact with a cooler surface a change of state from gaseous to liquid occurs.

Consistency The degree of plasticity of fresh concrete or mortar The normal measure of consistency is slump for concrete and flow for mortar.

Consolidation - Compaction usually accomplished by vibration of newly placed concrete to minimum practical volume, to mold it within form shapes and around embedded parts and reinforcement, and to eliminate voids other than entrained air.

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Construction Joint The contact between the placed concrete and concrete surfaces, against or upon which concrete is to be placed and to which new concrete is to adhere, that has become so rigid that the new concrete cannot be incorporated integrally by vibration with that previously placed. Unformed construction joints are horizontally placed or nearly so.

Cure Method of maintaining sufficient internal humidity and proper temperature for freshly placed concrete to assure proper hydration of the cement, and proper hardening of the concrete.

Density Weight per unit volume.

Dispersing Agent An admixture capable of increasing the fluidity of pastes, mortars, or concretes by reduction of interparticle attraction.

Dry Rodded Weight The weight of dry aggregate rodded into a cylindrical container of diameter approximately equal to the height, each of 3 layers rodded 25 times, and the excess aggregate struck off level with the top of the container

Drying Shrinkage A decrease in the volume of concrete upon drying.

Durability The ability of concrete to resist weathering action, chemical attack, and abrasion.

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Efflorescence A crystalline deposit of salts which leach from the concrete as soluble calcium hydroxides and within a short period of time will combine with the atmospheric carbon dioxide to form insoluble calcium carbonates, usually white in color, appearing on the surfaces of masonry, stucco or concrete.

Elastic Shortening The shortening of a member in pre-stressed concrete which occurs on the application of forces induced by prestressing.

Entrained Air (See air entrainment) Microscopic air bubbles intentionally incorporated in mortar or concrete, to improve workability and durability (usually imparting a higher degree of resistance to freezing and thawing).

Entrapped Air Air in concrete which is not purposely en-trained, Entrapped air bubbles are normally much larger and more irregular than entrained air bubbles.

False Set The rapid development of rigidity in a mixed portland cement paste, mortar, or concrete without the evolution of much heat. This rigidity can be dispelled and plasticity regained by further mixing without addition of water. Premature stiffening, and rubber set are terms referring to the same phenomenon, but false set is the preferred term.

Fine Aggregate Aggregate passing the 3/8-in. sieve and almost entirely passing the No.4(4.76 mm) sieve and predominantly retained on the No. 200 (74 micron) sieve(ASTM125).

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Flash Set The rapid development of rigidity in a mixed portland cement paste, mortar or concrete usually with the evolution of considerable heat, which rigidity cannot be dispelled nor can the plasticity be regained by further mixing without addition of water Also referred to as quick set or grab set.

Flexural Strength A property of a solid that indicates its ability to withstand bending.

Fly Ash The finely divided residue that results from the combustion of ground or powdered coal, transported from the firebox through the boiler by flue gases.

Foam Concrete (See Cellular concrete)

Gap-graded Aggregate Aggregate containing particles of both large and small sizes, in which particles of certain intermediate sizes are wholly or substantially absent.

Gas Concrete (See cellular concrete)

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Gillmore Needle A device used in determining time of setting of hydraulic cement, described in ASTM 0 266. Gradation The sizing of granular materials; for concrete materials, usually expressed in terms of cumulative percentages larger or smaller than each of a series of sieve openings or the percentages between certain ranges of sieve openings.

Grout A fluid mixture of (1) cement, sand, and water or (2) cement and water: the hardened equivalent of such mixtures.

Gunite A term sometimes used to designate dry-mix shotcrete.

Heat of Hydration The quantity of heat expressed in calories per gram, evolved upon complete hydration of portland cement at a given temperature.

Holding Period Period In the manufacture of concrete products, the period between completion of casting and the introduction of additional heat or the steam curing period.

HRM High Reactivity Metakaolin. Refined form of an ASTM C618, Class N (natural) pozzolan. A high performance, mineral admixture, similar in performance to silica fume, additionally comparable in cost. Pure white

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Process: Produced by heating a purified kaolinite clay to a specific high temperature to alter the physical composition (calcined). Through a carefully controlled refining process, impurities are removed producing an almost 100% reactive, pure white, pozzolanic powder, very evenly distributed in particle size and results in a mineral admixture which is consistent in appearance and performance from lot to lot.

Hydration Formation of a compound by the union of water with some other substance. In concrete it is the chemical reaction between water and the cement. A concrete slab needs to completely hydrate prior to the application of paints, coatings, and flooring materials.

Hydraulic Cement A cement that is capable of setting and hardening under water due to interaction of water and the constituents of the cement (ASTM 219).

Hydrogenesis Another term for condensation. The term is especially applied to base and soil substrates under highway pavements. where the barometric pump causes the inhalation of humid air, which then condenses in those structures, causing an ever increasing moisture content and sometimes instability.

Hydrologic Cycle The Hydrologic Cycle consists of the evaporation of water from oceans and other bodies of open water; condensation to produce cloud formations; precipitation of rain, snow, sleet or hail upon land surfaces; dissipation of rain or melted solids by direct run-off into lakes and by seepage

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Impermeable The ability of a material or product to reduce or eliminate gaseous transmissions through it's mass; measured as the rate of Water Vapor Transmission (WVT). Note: Not all materials that are waterproof are vaporproof; all materials that are vaporproof are inherently waterproof.

Initial Set A degree of stiffening of the cement and water mixture. This is a degree lees than final set and is generally stated as an empirical value, indicating the time in hours and minutes required for a cement paste to stiffen sufficiently to resist to an established degree the penetration of a weighted test needle. (Refer to ASTM C191 or C286 for weight and penetration data.)

Initial stress In prestressed concrete, the stresses occurring in the prestressed members before any losses occur.

Jacking Equipment In prestress concrete, the device used to stress the tendons.

Jacking Force The temporary force exerted by the jacking device which introduces tension into the tendons. Jacking Stress In prestress concrete, the maximum stress occurring in a tendon during stressing.

Keene's Cement A finely ground high density plaster composed of anhydrous, (calcined or "dead burned") gypsum, the set of which is accelerated by the addition of other materials.

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Kelly Ball A device for determining the consistency of fresh concrete. It is sometimes used as an alternative to the slump test.

Laitance A residue of weak and non-durable material consisting of cement, aggregate, fines, or impurities brought to the surface of overwet concrete by the bleeding water

Lift Layer of concrete.

Liquefaction The change of state to a liquid. Term used instead of condensation in reference to substances, which are usually gaseous.

Magnetite An aggregate used in heavy weight concrete, consisting primarily of ferrous metaferrite (Fe304). A black magnetic iron ore with a specific gravity of approximately 5.2 and a Mohs hardness of about 6.

Marl A calcareous clay, containing approximately 30 to 65 percent calcium carbonate (05003), found normally in extinct fresh wafer basins, swamps, or bottoms of shallow lakes.

Masonry Cement Hydraulic cement manufactured for use in mortars for masonry construction. Normally a blend of two or more of the following materials: portland cement, natural cement, portland-pozzolan cement, hydraulic lime, slag cement, hydrated lime, pulverized limestone, talc, chalk, pozzolan, clay or

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Mass Concrete Any large volume of concrete cast in place intended to resist applied loads by virtue of mass. Generally a monolithic structure incorporating a low cement factor with a high proportion of large coarse aggregate.

Mass Curing Adiabatic curing, using sealed containers.

Maximum Size Aggregate Aggregate whose largest particle size is present in sufficient quantity to affect the physical properties of concrete; generally designated by the sieve size on which the maximum amount permitted to be retained is 5 or 10 percent by weight.

Mixer Equipment used for mixing or blending the materials used in the manufacture of concrete, grout or mortar.

Mixing Speed Rate of mixer drum rotation or that of the paddles in a pan, open- top, or trough type mixer, when mixing a batch; expressed in revolutions per minute (rpm) or in peripheral] feet per minute of A point on the circumference at maximum diameter.

Mixing Time For stationary mixers, mixing time is calculated in minutes from the completion of charging the mixer until the beginning of discharge; for truck mixer, time is calculated in total minutes at a specified mixing speed. the period during which materials used in a batch of concrete are combined by the mixer

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Modulus of Elasticity A measure of the resistance of material to deformation. the ratio of normal stress corresponding strain for tensile or compressive stresses below the proportional limit of the material; elastic modulus is denoted by the symbol "2".

Moist Room A room used for storing and curing cementitious test specimens. The atmosphere of this room is maintained at a temperature of 73.4 3.0'F or 23.0*1.7'0 and relative humidity of at least 98 percent. These facilities must be adequate to continually maintain free moisture on the exteriors of test specimens.

Monolithic A plain or reinforced mass of concrete cast as a single, one piece, integral structure.

Mortar A mixture of cement, sand and water. When used in masonry construction, the mixture may contain masonry cement, or standard portland cement with lime or other ad-mixtures which may produce greater degrees of plasticity and/or durability.

Neat Cement Unhydrated hydraulic cement.

Neat Cement-Paste A mixture of water and hydraulic cement, both before and after setting and hardening.

No-Fines Concrete A concrete mixture in which only the coarse gradation (3/8' to 3/4' normally) of aggregate issued.

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Non-agitating Unit A truck-mounted unit for transporting ready-mixed concrete short distances, not equipped to provide agitation (slow mixing) during delivery.

Non-evaporable Water The water in concrete which is irremovable by oven drying; chemically combined during cement hydration.

Ottawa Sand A sand used as a standard in testing hydraulic cements by means of mortar test specimens. Sand is produced by processing silica rock particles obtained by hydraulic mining of the orthoquartzite situated in open-pit deposits near Ottawa, Illinois; naturally rounded grains of nearly pure quartz.

Overvibration Excessive vibration of freshly mixed concrete during placement- causing segregation.

Particle-Size Distribution Particle distribution of granular materials among various sizes; for concrete material normally designated as gradation. Usually expressed in terms of cumulative percentages smaller or larger than each of a series of sieve openings or percentages between certain ranges of sieve openings.

Pea Gravel Portion of concrete aggregate passing the 3/8' sieve and retained on a No.4 sieve.

Peeling A process in which thin flakes of matrix or mortar are broken away from

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Pining Development of relatively small cavities in a concrete surface, due to phenomena such as cavitation or corrosion.

Plane of Weakness The plane along which a structure under stress will tend to fracture; may exist because of the nature of the structure and its loading, by accident, or by design.

Plastic A condition of freshly mixed concrete. mortar or cement -paste indicating that it is workable and readily re-moldable, is cohesive, and has an ample content of fines and cement but is not over wet.

Plastic Consistency Condition in which concrete, mortar, or cement paste will sustain deformation continuously in any direction without rupture.

Plasticity Property of freshly mixed concrete, cement paste or mortar which determines its ease of molding or resistance to deformation.

Plasticizer A material that increases the workability or consistency of a concrete mixture, mortar or cement paste.

Porosity The ratio of the volume of voids in the material to the total volume of the material, including the voids, usually expressed as a percentage.

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Portland Blast- slag Cement Furnace (ASTM C 595)The product obtained by intimately intergrinding or an intimate and uniform blending a mixture of granulated blast furnace slag and portland-cement clinker

Portland Cement (ASTM C 150) the product obtained by pulverizing clinker consisting essentially of hydraulic calcium silicates.

Portland-Pozzolan Cement (ASTM C 595) The product obtained by intimately intergrinding a mixture of portland-cement clinker and pozzolan, or an intimate and uniform blend of portland cement and fine pozzolan.

Post-tensioning A method of prestressing concrete in which the tendons are tensioned after the concrete has hardened.

Pozzolan (ASTM C 618) A siliceous, or siliceous and aluminous material, which in itself possesses little or no cementitious value but will, in a finely divided form, such as a powder or liquid and in the presence of moisture, chemically react with calcium hydroxide at ordinary temperatures to form permanent, insoluble compounds possessing cementitious properties.

Precast A concrete unit, structure or member that is cast and cured in an area other than its final position or place.

Preplaced Concrete Concrete manufactured by placing clean, graded coarse

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Proportioning Selection of proportions of material for concrete to make the most economical use of available materials to manufacture concrete of the required strength, placeability, and durability,

Prestressed Concrete Concrete in which stresses have been introduced which are opposite in sense to those that the structural member will be expected to carry during its use.

Pretensioning A method of prestressing reinforced concrete in which the steel is stressed before the concrete has hardened and restrained from gaining its unstressed position by bond to the concrete.

Pumping (of Pavements) The ejection of a mixture of water and solid materials such as clay or silt along cracks, transverse or longitudinal joints, and along pavement edges caused by downward slab movement due to the passage of heavy loads, machinery or equipment over the pavement after free water has accumulated in or on the subbase, subgrade or basecourse.

Reactive Aggregate (See alkali-aggregate reaction)

Rebound Wet shotcrete or sand and cement which bounces away from a surface again at which pneumatically applied mortar is being projected.

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Refractory Concrete Concrete having refractory properties, suitable for use at high temperatures. Calcium-aluminate cement and refractory aggregates are normally used for the manufacture of this product.

Reinforced Concrete

A. Concrete in which reinforcement, other than that provided for temperature changes for shrinkage, has been embedded in such a- manner that the two materials act together in resisting forces.

B. Concrete in which steel bars have been placed to sustain the tensile stresses.

Retardation Delaying the hardening or strength gain of fresh concrete, mortar or grout.

Retarder An admixture which extends the setting time of cement paste, and therefore of mixtures such as concrete, mortar, or grout.

Retempering The addition of water and remixing of concrete which has started to stiffen: usually not allowed as it may affect the ultimate strength.

Revibration Delayed vibration of concrete that has already been placed and consolidated. Most effective when done at the latest time a running vibrator will sink of its own weight into the concrete and make it plastic and workable again.

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Rod (tamping) (ASTM C24l) A round, straight steel rod, 5/8' in diameter and approximately 24' in length, having the tamping end rounded into a hemispherical tip, the diameter of which is 5/8'.

Sack A quantity of cement: 94 Ibs. in the United States, 87.5 Ibs. in Canada, for portland or air entraining portland cement, or as indicated on the sack for other kinds of cement.

Sacking Removing or alleviating defects on a concrete surface by applying a mixture of sand and cement to the moistened surface and rubbing with a coarse material such as burlap.

Sand (ASTM C125) That portion of an aggregate passing the No. 4 (4.76 mm) sieve and predominantly retained on the No. 200 (74 micron) sieve.

Sand Blast A system of abrading a surface such as concrete by a stream of sand, or other abrasive, ejected from a nozzle at high speed by water and/or compressed air.

Saponification The deposit of a gray scum or gray dust on the inside surface of a subgrade wall or floor; as the result of moisture moving through the concrete and washing certain chemicals from the concrete mass.

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Scaling The breaking away of a hardened concrete surface, usually to a depth off/IS' to 3/16'.

Screed

1. Firmly placed grade strips or side forms which are set as guides for a straight edge to bring the surface of concrete to the required elevation.

2. To strike off concrete above the desired level.

Screen (or Sieve) A metallic sheet or plate, woven wire cloth, or similar device, with regularly spaced openings of uniform size, mounted in a suitable frame or holder for use in separating material according to size.

Segregation The tendency for the coarse particles to separate from the finer particles in handling. In concrete, the coarse aggregate and drier material remains behind and the mortar and wetter material flows ahead. This also occurs in a vertical direction when wet concrete is over vibrated or dropped vertically into the forms, the mortar and wetter material rising to the top. In aggregate, the coarse particles roll-to the outside edges of the stockpile.

Set A term used to describe the stiffening of cement paste; a condition reached by a concrete, cement paste, or mortar when plasticity is lost to an arbitrary degree, usually measured in terms of resistance to penetration or deformation. (Initial set refers to first stiffening. Final set refers to attainment of significant rigidity.)

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Setting Time The time required for a specimen of cement paste, mortar or concrete, prepared and tested under standardized conditions to attain a specified degree of rigidity with particular reference to initial and final setting time.

Shotcrete Mortar or concrete conveyed through a hose and projected pneumatically at high velocity onto a surface; dry-mix shotcrete (gunite), and wet- mix shotcrete.

Sieve See "Screen"

Sieve Analysis Determination of the proportions of particles of The granular material lying within certain size ranges on sieves of different size openings.

Slip Form A form which is raised or pulled as concrete is placed; may move vertically to form wails, stacks, bins or silos, usually of uniform cross section from bottom to top; or a generally horizontal direction to lay concrete evenly for highways, on slopes and inverts of canals, tunnels, and siphons.

Slump A measure of the consistency of plastic concrete relative to the amount it falls when a slump cone filled with concrete is lifted vertically. The slump cone is then placed beside the specimen of concrete and the number of inches from the top of the cone to the top of the of specimen of concrete is the slump. (see ASTM C143).

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Slurry A mixture of water and such finely divided materials, such as portland cement, slag, or soil in suspension.

Spall A fragment, usually of flaky shape, detached from a larger mass by pressure, expansion from within the larger mass, a blow, or by the action of weather.

Specific Gravity The ratio of the weight of a material at a stated temperature to the weight of the same volume of gas-free distilled water at a stated temperature.

Stucco A portland cement mortar material that can be applied to the surface of any building or structure to form a hard and durable covering for the exterior wails or other exterior surfaces.

Sulfate Attack Deleterious chemical and/or physical re-action between sulfates in ground water or soil and certain constituents in cement, which result in expansion and disruption of the concrete.

Sulfate Resistance Ability of cement paste, aggregate, or mixtures thereof to withstand sulfate attack.

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Temper The addition of water to the cement mix whether at the batch plant, during transit or at the jobsite to achieve the specified water to cement ratio.

Temperature Reinforcement Reinforcement used to carry temperature stresses.

Temperature Rise The increase of concrete temperature caused by heat of hydration and heat from other sources.

Tilt-up A method of concrete construction such as where members are cast horizontally near their eventual position, usually on a recently placed slab, and then tilted into place after removal of forms.

Transit-Mixed Concrete Concrete produced from a central-batching plant, where the materials are proportioned and placed in truck-mixers for mixing enroute to the job or after arrival there.

Tremie A pipe through which concrete may be placed under water, having at its upper end a hopper for filling, and a bale which permits handling of the assembly by a derrick.

Truck Mixer A concrete mixer capable of mixing concrete in transit when

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Ultimate Strength The maximum resistance to loads that a structure or member is capable of developing before failure occurs, or, with reference to cross sections of members, the largest axial force, shear or moment a structural concrete cross section will support.

Unit Water Content The quantity of water per unit volume of freshly mixed concrete, often expressed as gallons or pounds per cubic yard. This is the quantity of water on which the water cement ratio is based, and does not include water absorbed by the aggregate

Vapor Pressure The pressure exerted by a vapor that is calculated based upon relative humidity and temperature. The higher the humidity and higher temperature, in degrees Fahrenheit, the greater the vapor pressure exerted.

Vapor When a liquid changes to a gaseous form. The ability of the gas to hold moisture will reduce as temperatures reduce; more moisture can be contained in the gas as the temperatures increase.

Vaporproof A material that is totally immune to the passage of a gas under pressure. Any material that is truly vaporproof will inherently be waterproof.

Vibration Energetic agitation of concrete to assist in its consolidation, produced by mechanical oscillating devices at moderately high frequencies.

A. External vibration employs a device attached to the forms and is

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B. Internal vibration employs an element which can be inserted into the concrete; and is more generally used for cast-in-place construction.

Vicat Apparatus A penetration device used to determine the setting characteristics of hydraulic cements.

Wagner Fineness The fineness of materials such as portland cement expressed as total surface area in centimeters per gram as determined by the Wagner turbidimeter apparatus and procedure.

Water-Cement Ratio The ratio of the amount of water, exclusive of that absorbed by the aggregates, to the amount of cement in a concrete mix. Typically expressed as percentage of water, by weight in pounds, to the total weight of portland cement, fly ash, and any other cementitious material, per cubic yard, exclusive of any aggregates.

Waterproof A material or surface that is impervious or unaffected by water in its liquid form.will repel water in it's liquid form but may not necessarily be vaporproof.

Water Vapor Pressure The pressure exerted by water vapor. Air that contains higher amounts of water vapor exerts a higher vapor pressure than air which has a lower amount of has a higher water vapor pressure In concrete water vapor pressure is calculated by the difference between the vapor pressure of the concrete and the ambient relative humidity and temperature and in contact with

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Wetting Agent A substance capable of lowering the surface tension of liquids, facilitating the wetting of solid surfaces and permitting the penetration of liquids into the capillaries.

Workability The ease with which a given set of materials can be mixed into concrete and subsequently handled, transported, placed and finished with a minimum loss of homogeneity.

Yield The amount of concrete produced by a given combination of materials, the total weight of ingredients divided by the unit weight of the freshly mixed concrete; also, The cubic test of concrete produced per sack of cement; also, the number of product units, such as block, produced per batch of concrete or sack of cement.

Contributions: Kaiser Cement, Portland Cement Association, Concrete Manual, Bureau of Reclamation, U. S. Department of the Interior and many other publications, with special thanks to Bob Cameron of W. R. Meadows, MOXIE International, Inc., © 2001, All Rights Reserved.

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http://www.moxie-intl.com/glossary.htm (31 of 31) [5/15/2004 9:25:31 AM] Maintenance Glossary

Glossary of Maintenance Management Terms

This glossary is taken from the book Managing Factory Maintenance by Joel Levitt.

Asset: Either a machine, building, or system. It is the basic unit of maintenance.

Autonomous maintenance: Routine maintenance and PM's are carried out by operators in independent groups. These groups, which may include maintenance workers, solve problems without management intervention. The maintenance department is only officially called for bigger problems that require more resources, technology, or downtime.

Backlog: All work available to be done. Backlog work has been approved, parts are either listed or bought, and everything is ready to go.

BNF equipment: Equipment left off of the PM system, left in the Bust 'N Fix mode (it busts and you fix-no PM at all).

Call back: Job where the maintenance person is called back because the asset broke again or the job wasn't finished the first time. (See Rework.)

Capital spares: Usually large, expensive, long-leadtime parts that are capitalized (not expensed) on the books and depreciated. They are protection against downtime.

Certificate of insurance: A document from the insurance company that verifies insurance coverage for contractors on larger jobs. It will have dates that coverage is in effect, and the dollar limits and types of the coverage.

Charge-back: Maintenance work that is charged to the user. All work orders should be costed and billed back to the user's department. The maintenance budget is then included with the user budgets. Also called rebilling.

Charge rate: This is the rate in dollars that you charge for a mechanic's time. In addition to the direct wages, you add benefits and overhead (such as supervision, clerical support, shop tools, truck expenses, supplies). You might pay a tradesperson $15/hr and use a $35/hr (or greater) charge rate.

CM: See Corrective maintenance.

Computerphobia: Irrational fear or dread of computers.

Continuous improvement: Reduction to the inputs (hours, materials, management time) to maintenance to provide a given level of maintenance service. Increases in the number of assets, or use of assets with fixed or decreasing inputs.

Core damage: When a normally rebuildable component is damaged so badly that it cannot be repaired.

Corrective maintenance (CM): Maintenance activity that restores an asset to a preserved condition. Normally initiated as a result of a scheduled inspection. (See Scheduled work.)

Deferred maintenance: This is all of the work you know needs to be done that you choose not to do. You put it off, usually in hope of retiring the asset or getting authorization to do a major job that will include the deferred items.

DIN work: "Do It Now" means nonemergency work that you have to do now. An example would be moving furniture in the executive wing.

Emergency work: Maintenance work requiring immediate response from the maintenance staff. Usually associated with some kind of danger, safety, damage, or major production problems.

FAS: Shipping term meaning Free Along Side (you are responsible for the loading charge), commonly used for ships or very large freight.

Feedback: When used in the maintenance PM sense, feedback means information from your individual failure history is accounted for in the task list. The list is increased in depth or frequency when failure history is high, the list is decreased when failure history is low.

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FOB (City, Shipping point, or Defivered): Free On Board (seller will load truck or rail car). The FOB point is important because of both the responsibility for the shipment and the freight charges. "FOB delivered" keeps the vendor responsible for the shipment until it reaches your door. "FOB shipping point" or "FOB originating city" makes you responsible for the shipment. If there is a problem with an FOB originating city shipment, you still have to pay the vendor and file a claim with the carrier.

Frequency of inspection: How often do you do the inspections? What criteria do you use to initiate the inspection? (See PM clock.)

Future benefit PM: PM task lists that are initiated by a break-down rather than a usual schedule. The PM is done on a whole machine, assembly line, or process after a section or subsection breaks down. This is a popular method with manufacturing cells where the individual machines are closely coupled. When one machine breaks, then the whole cell is PM'ed.

GLO: Generalized Learning Objective means the general items necessary to know to be successful in a job. Each job description would be made up of a series of GLO's.

Iatrogenic: Failures that are caused by your own service person.

IBM® compatible: A personal computer that follows the rules of the IBM®-type machine. The rules include type of microprocessor chip, setup of internal wiring, ways to communicate, and others. All of the software examples in this text are based on this standard. It is also the most common standard in business. The other standard is based on the Apple Macintosh®. Many of the programs are also available for Apple systems.

In-bin work: Maintenance jobs which are not ready to release to the mechanic because you haven't approved or gotten money, parts are on order and not in, or other problem.

Inspection list: See Task list.

Inspectors: The special crew or special role that has primary responsibility for PM's. Inspectors can be members of the maintenance department or of any other department (machine operators, drivers, security officers, custodians, etc.).

Interruptive (task): Any PM task which interrupts the normal operation of a machine, system, or asset.

Labor: Physical effort a person has to expend to repair, inspect, or deal with a problem. It is expressed in hours, and can be divided by crafts or skills.

Life cycle: This denotes the stage in life of the asset. Three stages are recognized by the author: startup, wealth, breakdown.

Life cycle cost (LCC): A total of all costs throughout all of the life cycles. Costs should include PM, repair (labor, parts, and supplies), downtime, energy, ownership, overhead. An adjustment can be made for the time value of money.

Log sheet: A document where you make log entry of all small jobs or short repairs.

MTBF: Mean Time Between Failures. Important calculation to help set up PM schedules and to determine reliability of a system.

MTTR: Mean Time To Repair. This calculation helps determine the cost of a typical failure. It also can be used to track skill level, training effectiveness, and effectiveness of maintenance improvements.

Maintainability improvement: Also called maintenance improvement. Maintenance engineering activity that looks at the root cause of breakdowns and maintenance problems and designs a repair that prevents breakdowns in the future. Also includes improvements to make the equipment more easily maintained.

Maintenance: The dictionary definition is "the act of holding or keeping in a preserved state." The dictionary doesn't say anything about repairs. It presumes that we are acting in such a way to avoid the failure by preserving the asset.

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Maintenance prevention: Maintenance-free designs resulting from increased effectiveness in the initial design of the equipment.

Management: The act of controlling or handling.

Meter master: Form designed to record meter readings. There is also space for the subtraction for usage calculations.

MSDS: Material Safety Data Sheets. These sheets should come with any chemicals that you purchase. They give the formal name of the chemical, describe its toxicity, and have warnings on use. One master copy should be kept in the maintenance technical library.

Noninterruptive task list: PM task list where all of the tasks can safely be done without interrupting production of the machine.

Nonscheduled work: Work that you didn't know about and plan for at least the day before. Work falls into three categories: 1) emergency, 2) DIN, 3) routine.

Parts: All of the supplies, machine parts, and materials to repair an asset, or a system in or around an asset.

PCR: Planned Component Replacement. Maintenance schedules component replacement to a schedule based on MTBF, downtime costs, and other factors. Technique for ultrahigh reliability favored by the aircraft industry.

Pending work: Work that has been issued to a mechanic or contractor that is unfinished. It is important to complete all pending work.

Planned maintenance: See Scheduled work.

PM: Preventive Maintenance is a series of tasks that either extend the life of an asset, or that detect that an asset has had critical wear and is going to fail or break down.

PM clock: The parameter that initiates the PM task list for scheduling; usually buildings and assets in regular use (for example, PM every 90 days). Assets used irregularly may use other production measures such as pieces, machine hours, or cycles.

PM frequency: How often the PM task list will be done. Frequency is driven by the PM clock. (See Frequency of inspection.)

Predictive maintenance: Maintenance techniques that inspect an asset to predict if a failure will occur. For example, an infrared survey might be done of an electrical distribution system looking for hot spots (which would be likely to fail). In industry, predictive maintenance is usually associated with advanced technology such as infrared or vibration analysis.

Priority: The relative importance of the job. A safety problem would come before an energy improvement job.

Proactive: Action before a stimulus (opposite of reactive). A proactive maintenance department acts before a breakdown.

Reason for write-up (also called reason for repair): Why the work order was initiated. Reasons could include PM activity, capital improvements, breakdown, vandalism, and any others needed in that industry.

Rework: All work that has to be done over. Rework is bad and indicates a problem in materials, skills, or scope of the original job. (See Call back.)

RM: Replacement/ Rehabilitation/ Remodel Maintenance. All activity designed to bring an asset back into good shape, upgrade an asset to current technology, or make an asset more efficient/productive.

Root cause (root cause analysis): The root cause is the underlying cause of a problem. For example, you can snake out an old cast or galvanized sewer line every month and never be confident that it will stay open. The root cause is the hardened buildup inside the pipes which necessitates pipe replacement. Analysis would study the slow drainage problem and determine what was wrong and also estimate the cost of leaving it in place. Some problems (not usually this type of example) should not be fixed. Root cause analysis will show this.

http://www.maintenanceresources.com/ReferenceLibrary/CMMS/MaintGlossary.htm (3 of 5) [5/15/2004 9:47:17 AM] Maintenance Glossary

Route maintenance: Mechanic has an established route through your facility to fix all the little problems reported to them. The route mechanic is usually very well equipped so he/she can deal with most small problems. Route maintenance and PM activity are sometimes combined.

Routine work: Work that is done on a routine basis where the work and material content is well known and understood, for example, daily line startups.

Scheduled work: Work that is written up by an inspector and known about at least 1 day in advance. The scheduler will put the work into the schedule to be done. Sometimes the inspector finds work that must be done immediately which becomes emergency or DIN. Same as planned maintenance or corrective maintenance.

Short repairs: Repairs that a PM or route person can do in less than 30 minutes with the tools and materials that he/she carries.

SLO: Specific Learning Objective is the detailed knowledge, skill, or attitude necessary to be able to do a job.

SM: Seasonal Maintenance. All maintenance activities that are related to time of year or time in business cycle. Cleaning roof drains of leaves after the autumn would be a seasonal demand. A swimming pool chemical company might have some November activities to prepare for the next season.

String-based PM: Usually simple PM tasks that are strung to-gether on several machines. Examples of string PM's would include lubrication, filter change, or vibration routes.

Survey: A formal look around. All of the aspects of the facility are recorded and defined. The survey will look at every machine, room, and throughout the grounds. The surveyor will note anything that looks like it needs work.

SWO: Standing Work Order; work order for routine work. A standing work order will stay open for a week, month, or more. The SWO for daily furnace inspection might stay open for a whole month.

Task: One line on a task list (see below) that gives the inspector specific instruction to do one thing.

Task list: Directions to the inspector about what to look for during that inspection. Tasks could be to inspect, clean, tighten, adjust, lubricate, replace, etc.

Technical library (Maintenance Technical Library): The repository of all maintenance information including (but only limited by your creativity and space) maintenance manuals, drawings, old notes on the asset, repair history, vendor catalogs, MSDS, PM information, engineering books, shop manuals, etc.

Terotechnology: "A combination of management, financial, engineering, and other practices applied to physical assets in pursuit of economic life-cycle costs (LCC). Its practice is concerned with specification and design for reliability and maintainability of plant machinery, equipment, buildings, and structures with their installation, commissioning, maintenance, modification, and replacement, and with feedback of information on design, performance, and costs" (from the definition endorsed by the British Standards Institute).

TPM: Total Productive Maintenance. A maintenance system set up to eliminate all of the barriers to production. It uses autonomous maintenance teams to carry out most maintenance activity.

UM: User Maintenance. This is any maintenance request primarily driven by a user. It includes breakdown, routine requests, and DIN jobs.

Unit: The asset that the task list is written for in a PM system. The unit can be a machine, a system, or even a component of a large machine.

Work order: Written authorization to proceed with a repair or other activity to preserve a building or asset.

Work request: Formal request to have work done. Can be filled out by an inspector during an inspection on a write-up form or by a maintenance user. Work requests are usually time/date stamped.

http://www.maintenanceresources.com/ReferenceLibrary/CMMS/MaintGlossary.htm (4 of 5) [5/15/2004 9:47:17 AM] Maintenance Glossary

To order Managing Factory Maintenance by Joel Levitt through this website please Click Here.

This information is reprinted courtesy of Industrial Press. It is excerpted from Managing Factory Maintenance.

Return to CMMS Reference Articles Index

http://www.maintenanceresources.com/ReferenceLibrary/CMMS/MaintGlossary.htm (5 of 5) [5/15/2004 9:47:17 AM] Pipefitting Glossary of Terms

Pipefitting Glossary of Terms

Alloy Steel A steel which owes its distinctive properties to elements other than carbon.

Area of a Circle The measurement of the surface within a circle. To find the area of a circle, multiply the product of the radius times the radius times Pi (3.142).

Braze Weld or Brazing A process of joining metals using a nonferrous filler metal or alloy, the melting point of which is higher than 800 degrees F(427 degrees C) but lower than that of the metals to be joined.

Butt Weld A circumferential weld in pipe fusing the abutting pipe walls completely from inside wall to outside wall.

Carbon Steel A steel which owes its distinctive properties chiefly to the various percentages of carbon (as distinguished from the other elements) which it contains.

Circumference of a Circle The measurement around the perimeter of a circle. To find the circumference, multiply Pi (3.142) by the diameter.

Coefficient of Expansion A number indicating the degree of expansion or contraction of a substance. The coefficient of expansion is not constant and varies with changes in temperature. For linear expansion it is expressed as the change in length of one unit of length of a substance having one degree rise in temperature.

Corrosion The gradual destruction or alteration of a metal or alloy caused by direct chemical attack or by electromechanical reaction.

Creep The plastic flow of pipe within a system; the permanent set in metal caused by stresses at high temperatures. Generally associated with a time rate of deformation.

Diameter of a Circle A straight line drawn through the center of a circle from one extreme edge to the other. Equal to twice the radius.

Ductility The property of elongation, above the elastic limit, but under the tensile strength. A measure of ductility is the percentage of elongation of the fractured piece over its original length.

Elastic Limit The greatest stress which a material can withstand without a permanent deformation after release of the stress.

http://www.maintenanceresources.com/ReferenceLibrary/Pipefitting/pgot.htm (1 of 3) [5/15/2004 9:47:20 AM] Pipefitting Glossary of Terms

Erosion The gradual destruction of metal or other material by the abrasive action of liquids, gases, solids or mixtures thereof

Radius of a Circle A straight line drawn from the center to the extreme edge of a circle.

Socket Fitting A fitting used to join pipe in which the pipe is inserted into the fitting. A fillet weld is then made around the edge of the fitting and the outside wall of the pipe.

Soldering A method of joining metals using fusable alloys, usually tin and lead, having melting points under 700 degrees F(371 degrees C).

Strain Change of shape or size of a body produced by the action of a stress.

Stress The intensity of the internal, distributed forces which resist a change in the form of a body. When external forces act on a body they are resisted by reactions within the body which are termed stresses.

Stress, Compressive One that resists a force tending to crush a body.

Stress, Shearing One that resists a force tending to make one layer of a body slide across another layer.

Stress, Tensile One that resists a force tending to pull a body apart. Stress, Torsional: One that resists forces tending to twist a body.

Tensile Strength The maximum tensile stress which a material will develop. The tensile strength is usually considered to be the load in pounds per square inch at which a test specimen ruptures.

Turbulence Any deviation from parallel flow in a pipe due to rough inner walls, obstructions or directional changes.

Velocity Time rate of motion in a given direction and sense, usually expressed in feet per second.

Volume of a Pipe The measurement of the space within the walls of the pipe. To find the volume of a pipe, multiply the length (or height) of the pipe by the product of the inside radius times the inside radius times Pi (3.142).

Welding

http://www.maintenanceresources.com/ReferenceLibrary/Pipefitting/pgot.htm (2 of 3) [5/15/2004 9:47:20 AM] Pipefitting Glossary of Terms

A process of joining metals by heating until they are fused together, or by heating and applying pressure until there is a plastic joining action. Filler metal may or may not be used.

Yield Strength The stress at which a material exhibits a specified inciting permanent set.

Return to the Pipefitting Reference Articles Index

http://www.maintenanceresources.com/ReferenceLibrary/Pipefitting/pgot.htm (3 of 3) [5/15/2004 9:47:20 AM] Shaft Coupling Glossary

Shaft Coupling Glossary

Alignment A condition where the axis or center lines of two shafts are in line or coaxial.

Angular Misalignment A condition where two shafts are not parallel. The axis or center lines of two shafts intersect at angles to each other.

Axial Expansion This is a lengthening of a shaft. It could be caused by thermal changes in environment or induced through the use of a sliding coupling.

Backlash A jarring reaction when starting or reversing a load, caused by play in a coupling.

Clearance Fit Also called a slip fit. This is the most popular fit because of its ease of installation. The bore is larger than the shaft. It maintains its position on the shaft through the use of a key and set screw.

Damping Reducing vibration.

Donut The elastomeric element in donut type elastomeric couplings.

Elastomeric A coupling that has resilient materials through which the power is transmitted. They are in some way attached to the coupling halves. They are usually made of rubber, synthetic rubber or plastic materials.

End Float Also called axial misalignment. It is a condition where shafts could be in angular and parallel alignment. However, the shafts move in and out relative to each other.

Horsepower The rate at which torque is applied. Since applied torque causes a shaft and its connected components to rotate, a certain RPM results. HP is calculated by the following equation:

HP = Torque (lb. -in.) x RPM 63,025

Inertia The tendency of matter to remain at rest, or if moving, to keep moving in the same direction. Examples of high inertia loads; fans and fly wheels.

Interference Fit Also called a shrink or press fit. It gets its name because the bore is actually smaller than the shaft it is to be mated

http://www.maintenanceresources.com/ReferenceLibrary/Shafts/scg.htm (1 of 2) [5/15/2004 9:47:26 AM] Shaft Coupling Glossary with. It is the strongest fit possible but requires heat or an hydraulic press to install

Parallel Misalignment A condition where the shaft axis or center lines of two shafts are parallel but offset from each other.

Shear Pin A protection device used on some couplings. To protect driver and driven equipment against overload. The pin is located between coupling halves and is machined to break or shear at a predetermined load allowing the driver side to free wheel

Spider The elastomeric element of a flexible jaw type coupling. Usually has 4 or 6 arms.

Shrouded Bolt The optional bolt arrangement available on rigid and gear couplings. It is used in very high speed applications. Bolts are installed with a socket wrench.

Thermal Expansion Lengthening of shafting caused by thermal changes in environment.

Torque The force required to turn a shaft multiplied by the radius at which the force is applied. Torque is calculated by the following equation:

Lb. In. Torque = Force (lb.) x Radius (in.)

Torsional Vibration There are two main kinds of torsional vibration: a continuous steady form that comes from reciprocating engines and an intermittent for in that comes from large synchronous electric motors or from the driven equipment side in steel rolling mills.

Return to the Shafts Reference Articles Index

http://www.maintenanceresources.com/ReferenceLibrary/Shafts/scg.htm (2 of 2) [5/15/2004 9:47:27 AM] The Internet Glossary of Pumps

Glossary Home Page ATTENTION ALL USERS! We have created a new version of this free online Glossary, with greatly increased functionality (FLASH MX-based!)

Please change your links to go to the ALL ABOUT PUMPS tutorial MX version home page, where a NEW AND IMPROVED version of this glossary is available, along with links to our other FLASH-MX products.

URL for the new online FLASH-based elearning portal:

http://www.animatedsoftware.com./elearning/index.html

THANK YOU FOR USING OUR PRODUCTS!

Note: This version of our Internet Glossary of Pumps will be left online for those with slow Internet connections and for the search Engine "Bots" (which don't search FLASH files very well), but it will not be upgraded to the look and feel of the MX project, and new definitions will link directly to the MX version.. We regret any inconvenience and stongly urge you to try out the MX version! A CD with the entire MX version of the Glossary of Pumps can be purchased for just $10.00.

http://www.animatedsoftware.com/pumpglos/pumpglos.htm (1 of 6) [5/15/2004 9:47:43 AM] The Internet Glossary of Pumps

This Glossary of Pumps is from ALL ABOUT PUMPS by Russell D. Hoffman. All entries are animated in the CD-ROM version of ALL ABOUT PUMPS (entries with asterisks are animated in this Internet version).

Air Lift Pump Gear Pump, Reversing Archimedes Screw Global Pump (tm) Archimedes Snail Ram Pump Gravi-Chek (tm) Pump Ball Piston Pump* Recessive Spiral Pump Hand Pump* Bent-Axis Piston Pump* Rotary Cam Pump Impeller Mechanism, Basic* Bilge Pump, Hand-Operated Scoopwheel Pump Impeller, Single Lobe Bucket Pump Screw Pump Impeller Mechanism, 2-Lobe Crescent Pump* Simplex Pump* Impeller Diffuser Pump Ctesibian Pump Sling Pump Impeller Diffuser, Multi-Stage Cylindrical Energy Module (tm)* Spiral Pump Infusion Pump Diaphragm Pump* Squeeze Bulb Jet Pump (Wells)* Discflo (tm) Pump Star Pump* Lift Disk Pump Double Diaphragm Pump* Sucker Rod Pump Lift Pump Drum-Mate (tm) Drum Pump Swash Plate Piston Pump* Magnetic Flux Pump Duplex Pump* Tesla Turbine Pump Newby's Minimum Fluid Dutch Pumps* Tire Pump Technique Pump Ericsson Hot Air Pump* Turbine Pump Peristaltic Pump* Finger Pump* Tympanum Drum Piston Pump* Fireboat Vacuum Pump Progressive Cavity Pump Fish Tank Diaphragm Pump Vane Pump Propeller Pump Force Pump, Double Acting* Volute Pump Pulser Pump Gear Pump* Watergun, Super Soaker (tm) Pumper Truck Gear Pump, Balanced Wobble Plate Piston Pump* Quimby Screw Pump Gear Pump, 2-lobe Wolfhart Principle Pump* Radial Piston Pump* Gear Pump, 3-Lobe* Rag Pump

http://www.animatedsoftware.com/pumpglos/pumpglos.htm (2 of 6) [5/15/2004 9:47:43 AM] The Internet Glossary of Pumps

CD-ROM -- only $59.95!

● This Glossary is a part of a complete educational tutorial about pumps! ● Mechanical pumps are the second most common machine in the world (after electric motors). ● Most people are unfamiliar with how the many different kinds of pumps work! ● Call us toll free to order the program on CD-ROM! Satisfaction Guaranteed!

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Other Internet sources for pump information:

Fluid Power Journal

Fluid Power Journal is the official publication of the Fluid Power Society. Their web site includes many sources for more information.

Hydraulic Institute

A non-profit industry (trade) association established in 1917. HI and its members are "dedicated to excellence in the engineering, manufacture, and application of pumping equipment. The Institute has a leading role in the development of pump standards in North America and worldwide."

http://www.animatedsoftware.com/pumpglos/pumpglos.htm (3 of 6) [5/15/2004 9:47:43 AM] The Internet Glossary of Pumps Lifewater

Sponsored by Lifewater Canada, a Federally incorporated (Canada) non- profit charitable organization. Lifewater volunteers build pumps in poor communities around the world. Their web site contains information about a variety of low-cost, easy- to-maintain, easy-to-build, human-powered, solar-powered and animal-powered pumps. While most of them fall into one or two broad categories (lift pumps, ram pumps, etc.), YES, they describe some pumps I don't have in this glossary (at least, not yet)! A valuable resource, with links to pump manufacturers and descriptive information for building pumps. They have been operational since 1994.

Flow Control Network

Flow Control Network -- A powerful source of fluid handling product and application information for engineers. Includes searchable database of more than 1,000 companies and more than 450 product categories. All back issues of Flow Control magazine are available online and keyword searchable! More than 20,000 registered fluid handling professionals utilize the Flow Control Network web site.

Pumpbiz.Com

Pumpbiz.com is a pump distributor (over 9000 pumps!) and also contains a pump selection program for automated help in choosing a pump.

Pump Zone

Sponsored by Pumps & Systems Magazine. Includes additional Internet pump connections and has an enormous amount of pump-related material as well. (J. Robert Krebs reviewed ALL ABOUT PUMPS and THE HEART, THE ENGINE OF LIFE in the March, 1996 issue of the printed version of Pumps & Systems.)

http://www.animatedsoftware.com/pumpglos/pumpglos.htm (4 of 6) [5/15/2004 9:47:43 AM] The Internet Glossary of Pumps

KEOHPS

KEOHPS -- Knowledge Engineering on Hydraulics and Pneumatic Systems. The project originated out of a work intitled "Artificial Intelligence Applied to Fluid Power Design- An Integrating Approach". This site is available in both English and Portuguese.

PUMP-FLO.COM

PUMP-FLO.com is "the global pump selection portal". PUMP-FLO.com is a FREE service to all users.

PUMPS- PROCESSES.COM

Pumps and Processes magazine is "devoted to the needs of the mechanics, operators and engineers who work with pumps". At their web site you can learn about the magazine, view articles from their current issue, apply for a subscription, contact their staff, etc..

NATIONAL GROUND WATER ASSOCIATION

As described at their web site, "The mission of NGWA is to enhance the skills and credibility of all ground water professionals, develop and exchange industry knowledge and promote the ground water industry and understanding of ground water resources."

http://www.animatedsoftware.com/pumpglos/pumpglos.htm (5 of 6) [5/15/2004 9:47:43 AM] The Internet Glossary of Pumps

Please do not place this Glossary on another web server without prior permission of the author (please link to it instead!). It will always be here, and always be free, and always be the latest version.

You may download it for offline browsing or printing as long as you do not remove our copyright notices and authorship notices. It is recommended that you redownload it occasionally since we will update it periodically.

If you add a link to it from another web site THANK YOU and please let us know!

Images for this glossary are captured from our ALL ABOUT PUMPS animated educational tutorial using software from AndroSoft.

Catalog / Site Map / Company Home page / Contact / Product Home Page

Last modified June, 2003 Webmaster: Russell D. Hoffman Copyright (c) Russell D. Hoffman

http://www.animatedsoftware.com/pumpglos/pumpglos.htm (6 of 6) [5/15/2004 9:47:43 AM] Plant Maintenance Resource Center - Maintenance Terminology Plant Maintenance Resource Center

Maintenance Terminology - Some Key Terms

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Home Articles Webstore Jobs Software Tools Links Search About Maintenance Terminology - Some Key Terms

By Sandy Dunn, Webmaster, Plant Maintenance Resource Center

Please request permission from the author before copying or distributing this article

In the eight years that I have been involved in maintenance management consulting, I have learned that there is nothing that is guaranteed to cause more confusion and heated discussions than the area of Maintenance Terminology. Every Maintenance professional has an opinion regarding the "true" meaning of common Maintenance terms, and yet, often, definitions vary widely from person to person. Ted McKenna and Ray Oliverson have even written a book on the subject, and I can understand why! While the British Standards Institution has developed a standard (BS 3811:1993) for terms used in 'Terotechnology' (Maintenance Management to you and me), the reality is that we are a long way from gaining universal agreement regarding the meaning of terms that are fundamental to our day to day work as Maintenance professionals. At the risk of putting forward yet another opinion on the matter, the following is a set of definitions that make sense to me, and that I have found useful over the years.

If any of your favorite terms are missing, or if you believe I have "got it wrong", please mail me and I would be happy to discuss the matter and/or incorporate additional terms in this article.

http://www.plant-maintenance.com/terminology.shtml (1 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

Actuarial analysis - Statistical analysis of failure data to determine the age-reliability characteristics of an item.

APL - See Applications Parts List

Applications Parts List - A list of all parts required to perform a specific maintenance activity. Typically set up as a standard list attached to a Standard Job for Routine Tasks. Not to be confused with a Bill of Materials.

Apprentice - a tradesperson (or craftsperson) in training

Asset - unlike in the accounting definition, in maintenance this is commonly taken to be any item of physical plant or equipment.

Asset Management - the systematic planning and control of a physical resource throughout its life. This may include the specification, design, and construction of the asset, its operation, maintenance and modification while in use, and its disposal when no longer required.

Asset Register - a list of all the Assets in a particular workplace, together with information about those assets, such as manufacturer, vendor, make, model, specifications etc.

Availability - the proportion of total time that an item of equipment is capable of performing its specified functions, normally expressed as a percentage. It can be calculated by dividing the equipment available hours by the total number of hours in any given period. One of the major sources of disagreement over the definition of availability is whether downtime should be divided by total hours, or by Scheduled Operating Time. For example, if your plant is only scheduled to operate 5 days a week, should downtime incurred over the weekend be included in the calculation of availability? The http://www.plant-maintenance.com/terminology.shtml (2 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology

view I take is that one of the prime goals of any organisation should be to maximise its Return on Assets. This can only be achieved by reducing the total downtime, regardless of whether this downtime was scheduled or not. For this reason, I prefer to use a definition of downtime that considers all downtime, as a proportion of total time, not scheduled operating time.

Available Hours - the total number of hours that an item of equipment is capable of performing its specified functions. It is equal to the total hours in any given period, less the downtime hours.

Average Life - how long, on average, a component will last before it suffers a failure. Commonly measured by Mean Time Between Failures.

Backlog - Work which has not been completed by the nominated 'required by date'. The period for which each Work Order is overdue is defined as the difference between the current date and the 'required by date'. All work for which no 'required by' date has been specified is generally included on the backlog. Backlog is generally measured in "crew-weeks", that is, the total number of labour hours represented by the work on the backlog, divided by the number of labor hours available to be worked in an average week by the work crew responsible for completing this work. As such, it is one of the common Key Performance Indicators used in maintenance.

Benchmarking - the process of comparing performance with other organisations, identifying comparatively high performance organisations, and learning what it is they do that allows them to achieve that high level of performance.

Bill of Materials - a list of all the parts and components that make up a particular asset. Not to be confused with an Applications Parts List.

http://www.plant-maintenance.com/terminology.shtml (3 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology

BOM - see Bill of Materials.

Breakdown - a specific type of failure, where an item of plant or equipment is completely unable to function.

Breakdown Maintenance - see No Scheduled Maintenance

Call-out - To summon a tradesperson to the workplace during his normal non-working time so that he can perform a maintenance activity (normally an emergency maintenance task)

CBM - see Condition Based Maintenance

CMMS - see Computerized Maintenance Management System

Component - a subassembly of an Asset, usually removable in one piece and interchangeable with other, standard components (eg. Truck engine).

Computerized Maintenance Management System - a computerized system to assist with the effective and efficient management of maintenance activities through the application of computer technology. It generally includes elements such as a computerised Work Order system, as well as facilities for scheduling Routine Maintenance Tasks, and recording and storing Standard Jobs, Bills of Materials and Applications Parts Lists, as well as numerous other features.

Condition Based Maintenance - an equipment maintenance strategy based on measuring the condition of equipment in order to assess whether it will fail during some future period, and then taking appropriate action to avoid the consequences of that failure. The condition of equipment could be monitored using Condition Monitoring, Statistical Process Control techniques, by monitoring equipment performance, or through the use of the Human Senses.

http://www.plant-maintenance.com/terminology.shtml (4 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology The terms Condition Based Maintenance, On-Condition Maintenance and Predictive Maintenance can be used interchangeably.

Condition Monitoring - the use of specialist equipment to measure the condition of equipment. Vibration Analysis, Tribology and Thermography are all examples of Condition Monitoring techniques.

Conditional Probability of Failure - The probability that an item will fail during a particular age interval, given that it survives to enter that age.

Contract Acceptance Sheet - A document that is completed by the appropriate Contract Supervisor and Contractor to indicate job completion and acceptance. It also forms part of the appraisal of the contractors performance.

Corrective Maintenance - Any maintenance activity which is required to correct a failure that has occurred or is in the process of occurring. This activity may consist of repair, restoration or replacement of components.

Craftsperson - Alternative to Tradesperson. A skilled maintenance worker who has typically been formally trained through an apprenticeship program.

Criticality - The priority rank of a failure mode based on some assessment criteria.

Defect - A term typically used in the maintenance of mobile equipment. A defect is typically a potential failure or other condition that will require maintenance attention at some time in the future, but which is not currently preventing the equipment from fulfilling its functions.

Discard task - The removal and disposal of items or parts. http://www.plant-maintenance.com/terminology.shtml (5 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology

Downtime - the time that an item of equipment is out of service, as a result of equipment failure. The time that an item of equipment is available, but not utilised is generally not included in the calculation of downtime.

Economic Life - the total length of time that an asset is expected to remain actively in service before it is expected that it would be cheaper to replace the equipment rather than continuing to maintain it. In practice, equipment is more often replaced for other reasons, including: because it no longer meets operational requirements for efficiency, product quality, comfort etc., or because newer equipment can provide the same quality and quantity of output more efficiently.

Emergency Maintenance Task - a maintenance task carried out in order to avert an immediate safety or environmental hazard, or to correct a failure with signficant economic impact.

Engineering Work Order - the prime document used to initiate an engineering investigation, engineering design activity or engineering modifications to an item of equipment.

Environmental Consequences - a failure has environmental consequences if it could cause a breach of any known environmental standard or regulation.

Equipment Life - this term often isn't very useful, in a practical sense. For example, if I was to tell you that my Aunt has an axe that she uses for chopping firewood, and in the last 40 years it has had 2 new axeheads and 5 new handles, how would you define the life of the axe? Perhaps it makes more sense to talk about Component Life. Also see Economic Life, Useful Life and Average Life for some more practical definitions.

Equipment Maintenance Strategies - the choice of routine

http://www.plant-maintenance.com/terminology.shtml (6 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology maintenance tasks and the timing of those tasks, designed to ensure that an item of equipment continues to fulfil its intended functions.

Estimated Plant Replacement Value - the estimated cost of capital works required to replace all the existing assets with new assets capable of producing the same quantity and quality of output. This is a key value often used in benchmarking activities.

Estimating Index - the ratio of Estimated Labor Hours required to complete the work specified on Work Orders to the Actual Labor Hours required to complete the work specified on those Work Orders, commonly expressed as a percentage. This is a commonly used measure of Labor productivity, particularly when there are well- defined Estimating standards. A figure of greater than 100% for the Estimating Index indicates a higher than standard level of productivity, while a figure of less than 100% indicates a lower than standard level of productivity.

EWO - see Engineering Work Order

Expert System - a software based system which makes or evaluates decisions based on rules established within the software. Typically used for fault diagnosis.

Fail-safe - an item is fail-safe if, when the item itself incurs a failure, that failure becomes apparent to the operating workforce in the normal course of events.

Failure - an item of equipment has suffered a failure when it is no longer capable of fulfilling one or more of its intended functions. Note that an item does not need to be completely unable to function to have suffered a failure. For example, a pump that is still operating, but is not capable of pumping the required flow rate, has failed. In Reliability Centered Maintenance terminology, a failure is often called a Functional Failure. Would you classify a planned

http://www.plant-maintenance.com/terminology.shtml (7 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology equipment shutdown as a failure? Would you classify a routine equipment shutdown at shift change as a failure? Under this definition, the answer in the first case would be yes, but in the second case would be no. The justification for the inclusion of planned shutdowns as failures is that a failure, as defined, causes a disruption to the desired steady-state nature of the production process, and therefore should, ideally, be avoided.

Failure Cause - see Failure Mode

Failure Code - a code typically entered against a Work Order in a CMMS which indicates the cause of failure (eg. lack of lubrication, metal fatigue etc.)

Failure Consequences - a term used in Reliability Centered Maintenance. The consequences of all failures can be classified as being either Hidden, Safety, Environmental, Operational, or Non- Operational.

Failure Effect - a description of the events that occur after a failure has occurred as a result of a specific Failure Mode. Used in Reliability Centered Maintenance, FMEA and FMECA analyses.

Failure Finding Interval - the frequency with which a Failure Finding Task is performed. Is determined by the frequency of failure of the Protective Device, and the desired availability required of that Protective Device.

Failure Finding Task - Used in Reliability Centered Maintenance terminology. A routine maintenance task, normally an inspection or a testing task, designed to determine, for Hidden Failures, whether an item or component has failed. A failure finding task should not be confused with an On-Condition Task, which is intended to determine whether an item is about to fail. Failure Finding tasks are sometimes referred to as Functional Tests.

Failure Mode - any event which causes a failure.

http://www.plant-maintenance.com/terminology.shtml (8 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology

Failure Modes, Effects and Criticality Analysis - a structured method of assessing the causes of failures and their effect on production, safety, cost, quality etc.

Failure Modes and Effects Analysis - a structured method of determining equipment functions, functional failures, assessing the causes of failures and their failure effects. The first part of a Reliability Centered Maintenance analysis is a Failure Modes and Effects Analysis.

Failure Pattern - the relationship between the Conditional Probability of Failure of an item, and its age. Failure patterns are generally applied to Failure Modes. Research in the airline industry established that there are six distinct failure patterns. The type of failure pattern that applies to any given failure mode is of vital importance in determining the most appropriate equipment maintenance strategy. This fact is one of the key principles underlying Reliability Centered Maintenance.

FFI - pronounced "Fifi", but has nothing to do with a French maid. See Failure Finding Interval

FMECA - see Failure Modes, Effects and Criticality Analysis

FMEA - see Failure Modes and Effects Analysis

Forward Workload - All known backlog work and work which is due or predicted to become backlog work within a pre-specified future time period.

FTA - Fault Tree Analysis

Function - The definition of what we want an item of equipment to do, and the level of performance which the users of the equipment require when it does it. Note that an item of equipment can have many functions, commonly split into Primary and Secondary Functions. Note also that the level of performance specified is that required by the users of the equipment, which may be quite different http://www.plant-maintenance.com/terminology.shtml (9 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology to the original design, or maximum, performance capability for the equipment.

Functional Failure - Used in Reliability Centered Maintenance terminology. The inability of an item of equipment to fulfil one or more of its functions. Interchangeably used with Failure.

Functional Test - see Failure Finding Task

Gantt Chart - A bar chart format of scheduled activities showing the duration and sequencing of activities.

Go-line - Used in relation to mobile equipment. Equipment which is available, but not being utilized is typically parked on the Go-line. This term is used interchageably with Ready Line.

Hazop - a structured process, originally developed by ICI following the Flixborough disaster, intended to proactively identify equipment modifications and/or safety devices required in order to avoid any significant safety or environmental incident as a result of equipment failure. Similar, in some respects to Reliability Centered Maintenance, but not as rigorous as Reliability Centered Maintenance in identifying underlying causes of failure, and does not consider, in any depth, the possibility of avoiding such incidents through applying appropriate Proactive Maintenance tasks.

Hidden Failure - a failure which, on its own, does not become evident to the operating crew under normal circumstances. Typically, protective devices which are not fail-safe (examples could include standby plant and equipment, emergency systems etc.)

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Infant Mortality - The relatively high conditional probability of failure during the period immediately after an item returns to service.

Inherent Reliability - A measure of the reliability of an item, in its present operating context, assuming adherence to ideal equipment maintenance strategies.

Inspection - Any task undertaken to determine the condition of equipment, and/or to determine the tools, labour, materials, and equipment required to repair the item.

J K

Key Performance Indicators - A select number of key measures that enable performance against targets to be monitored.

KPI - see Key Performance Indicators

Life - that strange experience you have all day, every day. In a maintenance context, you may want to look at Equipment Life.

LCC - see Life Cycle Costing

Life Cycle Costing - - a process of estimating and assessing the total costs of ownership, operation and maintenance of an item of equipment during its projected equipment life. Typically used in comparing alternative equipment design or purchase options in order to select the most appropriate option.

Logistic support analysis (LSA) - A methodology for determining the type and quantity of logistic support required for a system over its entire lifecycle. Used to determine the cost effectiveness of asset based solutions. http://www.plant-maintenance.com/terminology.shtml (11 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology

LSA - see Logistic Support Analysis

Maintainability - the ease and speed with which any maintenance activity can be carried out on an item of equipment. May be measured by Mean Time to Repair. Is a function of equipment design, and maintenance task design (including use of appropriate tools, jigs, work platforms etc.).

Maintainability Engineering - The set of technical processes that apply maintainability theory to establish system maintainability requirements, allocate these requirements down to system elements and predict and verify system maintainability performance.

Maintenance - any activity carried out on an asset in order to ensure that the asset continues to perform its intended functions, or to repair the equipment. Note that modifications are not maintenance, even though they may be carried out by maintenance personnel.

Maintenance Engineering - a staff function whose prime responsibility is to ensure that maintenance techniques are effective, that equipment is designed and modified to improve maintainability, that ongoing maintenance technical problems are investigated, and appropriate corrective and improvement actions are taken. Used interchangeably with Plant Engineering and Reliability Engineering.

Maintenance Policy - a statement of principle used to guide Maintenance Management decision making

Maintenance Schedule - a list of planned maintenance tasks to be performed during a given time period, together with the expected start times and durations of each of these tasks. Schedules can apply to different time periods (eg. Daily Schedule, Weekly Schedule etc.)

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Maintenance Strategy - a long-term plan, covering all aspects of maintenance management which sets the direction for maintenance management, and contains firm action plans for achieving a desired future state for the maintenance function.

Mean Time Between Failures - a measure of equipment reliability. Equal to the total equipment uptime in a given time period, divided by the number of failures in that period.

Mean Time To Repair - a measure of maintainability. Equal to the total equipment downtime in a given time period, divided by the number of failures in that period.

MIL-HDBK- United States Military Handbook

MIL-STD- United States Military Standard

Model Work Order - A Work Order stored in the CMMS which contains all the necessary information required to perform a maintenance task. (see also Standard Job)

Modification - any activity carried out on an asset which increases the capability of that asset to perform its required functions.

MTBF - see Mean Time Between Failures

MTTR - see Mean Time To Repair

NDT - see Non-Destructive Testing

No Scheduled Maintenance - an Equipment Maintenance Strategy, where no routine maintenance tasks are performed on the equipment. The only maintenance performed on the equipment is Corrective Maintenance, and then only after the equipment has suffered a failure. Also described as a Run-to-Failure strategy. http://www.plant-maintenance.com/terminology.shtml (13 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology

Non-Destructive Testing - testing of equipment, which does not destroy the equipment, to detect abnormalities in physical, chemical or electrical characteristics. For some reason which escapes me, vibration analysis and tribology are not generally considered to be NDT techniques, even though they meet the above criteria. Techniques which are considered to be NDT techniques are ultrasonic thickness testing, dye penetrant testing, x-raying, and electrical resistance testing.

Non-Operational Consequences - a failure has non-operational consequences if the only impact of the failure is the direct cost of the repair (plus any secondary damage caused to other equipment as a result of the failure.

Non-routine Maintenance - Any maintenance task which is not performed at a regular, pre-determined frequency.

Oil Analysis - see Tribology

On-Condition Maintenance - see Condition Based Maintenance

Operating Context - the operational situation within which an asset operates. For example, is it a stand-alone piece of plant, or is it one of a duty-standby pair? Is it part of a batch manufacturing process or a continuous production process? What is the impact of failure of this item of equipment on the remainder of the production process? The operating context has enormous influence over the choice of appropriate equipment maintenance strategies for any asset.

Operating Hours - the length of time that an item of equipment is actually operating.

Operational Consequences - a failure has operational consequences if it has a direct adverse impact on operational capability (lost production, increased production costs, loss of

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Operational Efficiency- used in the calculation of Overall Equipment Effectiveness. The actual output produced from an asset in a given time period divided by the output that would have been produced from that asset in that period, had it produced at its rated capacity. Normally expressed as a percentage.

Outage - a term used in some industries (notably power generation) which is equivalent to a shutdown.

Overall Equipment Effectiveness - a term initially coined in connection with Total Productive Maintenance. It provides a measure of overall asset productivity. Is generally expressed as a percentage, and can be calculated by multiplying Availability by Utilization by Operational Efficiency by Quality Rate.

Overhaul - a comprehensive examination and restoration of an asset to an acceptable condition.

P-F Interval - a term used in Reliability Centered Maintenance. The time from when a Potential Failure can first be detected on an asset or component using a selected Predictive Maintenance task, until the asset or component has failed. Reliability Centered Maintenance principles state that the frequency with which a Predictive Maintenance task should be performed is determined solely by the P-F Interval.

PdM - see Predictive Maintenance

Percent Planned Work - the percentage of total work (in labour hours) performed in a given time period which has been planned in advance.

PERT Chart - see Project Evaluation & Review Technique (PERT)

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Planned Maintenance - any maintenance activity for which a pre- determined job procedure has been documented, for which all labour, materials, tools, and equipment required to carry out the task have been estimated, and their availability assured before commencement of the task.

Plant Engineering - - a staff function whose prime responsibility is to ensure that maintenance techniques are effective, that equipment is designed and modified to improve maintainability, that ongoing maintenance technical problems are investigated, and appropriate corrective and improvement actions are taken. Used interchangeably with Maintenance Engineering and Reliability Engineering.

PM - see Preventive Maintenance

Potential Failure - a term used in Reliability Centered Maintenance. An identifiable condition which indicates that a functional failure is either about to occur, or in the process of occurring.

PRA - see Probabalistic Risk Assessment

Predictive Maintenance - an equipment maintenance strategy based on measuring the condition of equipment in order to assess whether it will fail during some future period, and then taking appropriate action to avoid the consequences of that failure. The condition of equipment could be monitored using Condition Monitoring, Statistical Process Control techniques, by monitoring equipment performance, or through the use of the Human Senses. The terms Condition Based Maintenance, On-Condition Maintenance and Predictive Maintenance can be used interchangeably.

Preventive Maintenance - an equipment maintenance strategy based on replacing, overhauling or remanufacturing an item at a

http://www.plant-maintenance.com/terminology.shtml (16 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology fixed interval, regardless of its condition at the time. Scheduled Restoration tasks and Scheduled Discard tasks are both examples of Preventive Maintenance tasks.

Primary Function - a term used in Reliability Centered Maintenance. The primary functionality required of an asset - the reason the asset was acquired. For example it is likely that the primary function of a pump is to pump a specified liquid at a specified rate against a specified head of pressure.

Priority - the relative importance of a task in relation to other tasks. Used in scheduling work orders.

Proactive Maintenance - Any tasks used to predict or prevent equipment failures.

Probabalistic Risk Assessment - A "top-down" approach used to apportion risk to individual areas of plant and equipment, and possibly to individual assets so as to achieve an overall target level of risk for a plant, site or organisation. These levels of risk are then used in risk-based techniques, such as Reliability Centered Maintenance and Hazop, to assist in the development of appropriate equipment maintenance strategies, and to identify required equipment modifications.

Probabalistic Safety Assessment - Similar to Probabalistic Risk Assessment, except focused solely on Safety related risks.

Project Evaluation & Review Technique (PERT) Chart - Scheduling tool which shows in flow chart format the interdependencies between project activities.

Protective Device - Devices and assets intended to eliminate or reduce the consequences of equipment failure. Some examples include standby plant and equipment, emergency systems, safety valves, alarms, trip devices, and guards.

PSA - see Probabalistic Safety Assessment

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Purchase Requisition - The prime document raised by user departments authorising the purchase of specific materials, parts, supplies, equipment or services from external suppliers.

Purchase Order - The prime document raised by an organisation, and issued to an external supplier, ordering specific materials, parts, supplies, equipment or services.

Quality Rate - used in the calculation of Overall Equipment Effectiveness. The proportion of the output from a machine or process which meets required product quality standards. Normally specified as a percentage.

RCM - see Reliability Centered Maintenance

Ready Line - Used in relation to mobile equipment. Equipment which is available, but not being utilized is typically parked on the Ready Line. This term is used interchageably with Go-Line.

Redesign - a term which, in Reliability Centered Maintenance, means any one-off intervention to enhance the capability of a piece of equipment, a job procedure, a management system or people's skills

Reliability - the capability of an asset to continue to perform its intended functions. Normally measured by Mean Time Between Failures

Reliability Centered Maintenance - A structured process, originally developed in the airline industry, but now commonly used in all industries to determine the equipment maintenance strategies required for any physical asset to ensure that it continues to fulfil its intended functions in its present operating context. A number of http://www.plant-maintenance.com/terminology.shtml (18 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology books have been written on the subject, but none better than Moubray's book, RCM II.

Reliability Engineering - - a staff function whose prime responsibility is to ensure that maintenance techniques are effective, that equipment is designed and modified to improve maintainability, that ongoing maintenance technical problems are investigated, and appropriate corrective and improvement actions are taken. Used interchangeably with Plant Engineering and Maintenance Engineering.

Repair - any activity which returns the capability of an asset that has failed to a level of performance equal to, or greater than, that specified by its Functions, but not greater than its original maximum capability. An activity which increases the maximum capability of an asset is a modification.

Restoration - any activity which returns the capability of an asset that has not failed to a level of performance equal to, or greater than, that specified by its Functions, but not greater than its original maximum capability. Not to be confused with a modification or a repair.

Return on Assets - an accounting term. Let's not get into a lengthy discussion of the relative merits of various accounting standards, how assets should be valued (book value, replacement value, depreciation rates and methods etc.), and differences between tangible and intangible assets. This is the stuff that accountants have wet dreams over, but not maintenance engineers. In practical terms, as it impacts on maintenance, Return on Assets is the profit attributable to a particular plant or factory, divided by the amount of money invested in plant and equipment at that plant or factory. It is normally expressed as a percentage. As such, it is roughly equivalent (in principle - please excuse the pun!) to the interest rate that you get on money invested in the bank, except that in this case the money is invested in plant and equipment.

Risk - The potential for the realisation of the unwanted, negative consequences of an event. The product of conditional probability of http://www.plant-maintenance.com/terminology.shtml (19 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology

an event, and the event outcomes.

Rotable - a term often used in the maintenance of heavy mobile equipment. A rotable component is one which, when it has failed, or is about to fail, is removed from the asset and a replacement component is installed in its place. The component that has been removed is then repaired or restored, and placed back in the maintenance store or warehouse, ready for re-issue.

Routine Maintenance Task - any maintenance task that is performed at a regular, predefined interval.

Run-to-Failure - No Scheduled Maintenance - an Equipment Maintenance Strategy, where no routine maintenance tasks are performed on the equipment. The only maintenance performed on the equipment is Corrective Maintenance, and then only after the equipment has suffered a failure. Also described as a No Scheduled Maintenance strategy.

Safety Consequences - a failure has safety consequences if it causes a loss of function or other damage that could hurt or kill someone.

Schedule Compliance - one of the Key Performance Indicators often used to monitor and control maintenance. It is defined as the number of Scheduled Work Orders completed in a given time period (normally one week), divided by the total number of Scheduled Work Orders that should have been completed during that period, according to the approved Maintenance Schedule for that period. It is normally expressed as a percentage, and will always be less than or equal to 100%. The closer to 100%, the better the performance for that time period.

Scheduled Maintenance - any maintenance work that has been planned and included on an approved Maintenance Schedule.

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Scheduled Discard Task - a maintenance task to replace a component with a new component at a specified, pre-determined frequency, regardless of the condition of the component at the time of its replacement. An example would be the routine replacement of the oil filter on a motor vehicle every 6,000 miles. The frequency with which a Scheduled Discard task should be performed is determined by the Useful Life of the component.

Scheduled Operating Time - the time during which an asset is scheduled to be operating, according to a long-term production schedule.

Scheduled Restoration Task - a maintenance task to restore a component at a specified, pre-determined frequency, regardless of the condition of the component at the time of its replacement. An example would be the routine overhaul of a slurry pump every 1,000 operating hours. The frequency with which a Scheduled Restoration task should be performed is determined by the Useful Life of the component.

Scheduled Work Order - a Work Order that has been planned and included on an approved Maintenance Schedule.

Secondary Damage - Any additional damage to equipment, above and beyond the initial failure mode, that occurs as a direct consequence of the initial failure mode.

Secondary Function - a term used in Reliability Centered Maintenance. The secondary functionality required of an asset - generally not associated with the reason for acquiring the asset, but now that the asset has been acquired, the asset is now required to provide this functionality. For example a secondary function of a pump may be to ensure that all of the liquid that is pumped is contained within the pump (ie. the pump doesn't leak). An asset may have tens or hundreds of secondary functions associated with it.

Shutdown - that period of time when equipment is out of service.

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Shutdown Maintenance - Maintenance that can only be performed while equipment is shutdown

Standard Job - A Work Order stored in the CMMS which contains all the necessary information required to perform a maintenance task. (see also Model Work Order)

Standing Work Order - a work order that is left open either indefinitely or for a pre-determined period of time for the purpose of collecting labor hours. costs and/or history for tasks for which it has been decided that individual work orders should not be raised. Examples would include Standing Work Orders raised to collect time spent at Safety Meetings, or in general housekeeping activities.

Stores Issue - the issue and/or delivery of parts and materials from the store or warehouse.

Stores Requisition - The prime document raised by user departments authorising the issue of specific materials, parts, supplies or equipment from the store or warehouse.

Terotechnology - the application of managerial, financial, engineering and other skills to extend the operational life of, and increase the efficiency of, equipment and machinery.

Thermography - the process of monitoring the condition of equipment through the measurement and analysis of heat. Typically conducted through the use of infra-red cameras and associated software. Commonly used for monitoring the condition of high voltage insulators and electrical connections, as well as for monitoring the condition of refractory in furnaces and boilers, amongst other applications.

Total Asset Management - an integrated approach (yet to be developed!) to Asset Management which incorporates elements

http://www.plant-maintenance.com/terminology.shtml (22 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology such as Reliability Centered Maintenance, Total Productive Maintenance, Design for Maintainability, Design for Reliability, Value Engineering, Life Cycle Costing, Probabalistic Risk Assessment and others, to arrive at the optimum Cost-Benefit-Risk asset solution to meet any given production requirements.

TPM - see Total Productive Maintenance

Tradesperson - Alternative to Craftsperson. A skilled maintenance worker who has typically been formally trained through an apprenticeship program.

Tribology - the process of monitoring the condition of equipment through the analysis of properties of its lubricating and other oils. Typically conducted through the measurement of particulates in the oil, or the measurement of the chemical composition of the oil (Spectographic Oil Analysis). Commonly used for monitoring the condition of large gearboxes, engines and transformers, amongst other applications.

ToSS - see Total System Support

Total Productive Maintenance - a company-wide equipment management program, with its origins in Japan, emphasising production operator involvement in equipment maintenance, and continuous improvement approaches. Numerous books have been written on the subject, including Nakajima's authoritative introduction, and a more recent Western hemisphere update by Willmott.

Total System Support (ToSS) - The composite of all considerations needed to assure the effective and economical support of a system throughout its programmed life-cycle.

Unplanned Maintenance - any maintenance activity for which a pre-determined job procedure has not been documented, or for

http://www.plant-maintenance.com/terminology.shtml (23 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology which all labour, materials, tools, and equipment required to carry out the task have been not been estimated, and their availability assured before commencement of the task.

Unscheduled Maintenance - any maintenance work that has not been included on an approved Maintenance Schedule prior to its commencement.

Uptime - strangely enough, the opposite of downtime. It is defined as being the time that an item of equipment is in service and operating.

Useful Life - the maximum length of time that a component can be left in service, before it will start to experience a rapidly increasing probability of failure. The Useful Life determines the frequency with which a Scheduled Restoration or a Scheduled Discard task should be performed. Note that for the concept of the Useful Life of a component to hold true, components must, at some consistent point in time, experience a rapidly increasing probability of failure. Research in the airline industry showed that, in this industry at least, this was only true for 11% of the components in modern aircraft.

Utilization - the proportion of available time that an item of equipment is operating. Calculated by dividing equipment operating hours by equipment available hours. Generally expressed as a percentage

Value Engineering - a systematic approach to assessing and analyzing the user's requirements of a new asset, and ensuring that those requirements are met, but not exceeded. Consists primarily of eliminating perceived "non-value-adding" features of new equipment.

Vibration Analysis - - the process of monitoring the condition of equipment, and the diagnosis of faults in equipment through the measurement and analysis of vibration within that equipment.

http://www.plant-maintenance.com/terminology.shtml (24 of 25) [5/15/2004 9:47:57 AM] Plant Maintenance Resource Center - Maintenance Terminology Typically conducted through hand-held or permanently positioned accelerometers placed on key measurement points on the equipment. Commonly used on most large items of rotating equipment, such as turbines, centrifugal pumps, motors, gearboxes etc.

Work Order - The prime document used by the maintenance function to manage maintenance tasks. It may include such information as a description of the work required, the task priority, the job procedure to be followed, the parts, materials, tools and equipment required to complete the job, the labor hours, costs and materials consumed in completing the task, as well as key information on failure causes, what work was performed etc.

Work Request - The prime document raised by user departments requesting the initiation of a maintenance task. This is usually converted to a work order after the work request has been authorised for completion.

Workload - the amount of labor hours required to carry out specified maintenance tasks.

X Y Z

ZZZ - what you will be doing if you made it through this list!

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Maintenance Resources Search An Overview of Infrared Technology

This glossary is presented here courtesy of Inframetrics, manufacturers of infrared

this site the web cameras. Select from the following terms for a description of Infrared terminology.

Enter to WIN! Ambient Temperature Compensation ASIC (Application Specific Integrated CCD Readout Circuit) Products CMOS (Complementary Metal Oxide Chromatic Aberration Showcase Semiconductor) CMOS Detector FPA (Focal Point Array) Diffractive Lenses FREE Ezine Hybrid FPA Fill Factor

Reference Library Microbolometer FPA Indium Antimonide (InSb) FPA Multiplexer Monolithic FPA Discussion Boards Nonuniformity Correction Non-Reimaging Lens Design Quantum Efficiency Platinum Silicide (PtSi) FPA PEM Job-Line Reimaging Lens Design Quantum Well (QWIP) FPA Trade Show/ Variable Integration Time Seminar Search PEM Publications Ambient Temperature Compensation For years, it has been well understood that Free On-Line thermal imaging systems drift with variations in CMMS environmental temperature. This results from energy falling on the detector from components CMMS Links inside the camera such as the lenses and other internal objects. Each manufacturer has their PEM Links own approach for dealing with this problem. Approaches range from sophisticated algorithms Doing Business processing data that is collected from multiple With Us temperature sensors throughout the camera and lenses, to systems that employ no compensation Contact Us mechanism at all. Why should the P/PM user care about this feature? Due to the fluctuating nature of the environments that IR cameras are used in, the temperature of the camera and lenses vary significantly. This can cause rather sever drift if not properly compensated for. The drift manifests itself itself in the form of erroneous readings from the instrument. The most comprehensive approach to solving this problem is by instrumenting each contributing component in the system with a temperature sensor, then the system can be calibrated through a variety of ambient temperature conditions during the manufacturing process. This capability is particularly important if you intend to make decisions on repair criterion based on absolute temperature measurements or trended data.

ASIC (Application Specific Integrated Circuit)

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In an effort to reduce the size, power consumption and cost of FPA cameras, the processing electronics need to be highly efficient and powerful. One means of achieving this without needing to support the software overhead and power consumption of off the shelf processors designed for PC applications is to utilize custom processor technology packaged in an Application Specific Integrated Circuit (ASIC).

ASICs are very common today and are used in everything from photocopiers to cellular phones. The concept behind these devices is to design an electronics processor which has been optimized in all aspects of performance for the particular application. The resulting electronics design is then packaged into an IC which becomes an ASIC. ASICs typically use a fraction of the power associated with standard PC processors and do not require the high software overhead associated with the DOS operating environment. Most ASIC processors offer advanced capabilities such as field upgradeability and very fast processing speeds.

The use of ASIC technology has benefited P/PM users by making FPA instruments small, lighter and less power consuming. Typically devices based on ASIC technology have relatively long battery life and support easy to use controls. The bottom line is that the FPA instrument should not be compromised by the choice of processing technology with the instrument. Low power, high speed, upgradeable processors are most desirable for hand held FPA systems.

CCD Readout

Today's FPA detectors have two basic types of readouts for taking each detector's signal and getting it to the camera's signal processor. These are known as CCD (Charge Coupled Device) and CMOS. The CCD Detector operates in a mode where the signal from each detector is determined by transferring its electrons from one detector to the next down the row until it reaches the end column where it is read out. You can think of this by envisioning a bucket brigade where the contents of a bucket at the beginning of a line is transferred to the end of the line by passing it from bucket to bucket.

The CCD transfer process is not perfect, since some of the charge is lost along the way, much in the same way some water would be lost after passing it through 255 buckets. This is known as "Charge Couple Transfer Loss Phenomenon." Also, when one detector cell becomes overfilled with photons from a hot source, it can "overflow" into the adjacent detector cells. This is known as "blooming". CCD detectors require significantly more power than their CMOS counterparts and thus require higher powered cooling devices typically.

CCD detectors are widely used in imaging applications since the losses encountered by Charge Couple Transfer Loss Phenomenon and blooming are typically not relevant in non measurement scenarios. When a CCD detector is utilized in a measurement IF FPA camera, compensations must be done to reduce errors caused by this issue.

Chromatic Aberration

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Chromatic Aberration is a phenomenon where different wavelengths of light are not all focused at the same time. For example, 35mm cameras have had lenses that have "color correction" for years. What they mean by color correction is that the lens is designed to focus all colors of light simultaneously. So when you focus on a scene of a bouquet of flowers, each flower, regardless of its color will be in focus. If the lens did not have color correction, you might see an image where the red and yellow flowers were in focus, but the blue flowers would seem a bit fuzzy. This is known as chromatic aberration.

Chromatic aberration can occur in IR systems, since these systems typically sense energy over a wide range of wavelengths at one time. Without correction, you could have a scene in which energy at 3.5um is focused and energy at 5.0um is fuzzy. The result would be an overall image that would not be crisp and could be subject to measurement errors. Manufacturers of IR systems can correct for this problem by developing color corrected IR lenses. Typically this is done by having several optical elements in the lens just like is done with 35mm camera lenses.

CMOS (Complementary Metal Oxide Semiconductor)

Complementary Metal Oxide Semiconductor (CMOS) refers to a manufacturing technology which is used widely today in most electronic devices. To a large degree, CMOS technology is what made the production of IR FPAs possible.

In a CMOS device, a photochemical etching process is used to create tiny circuits known as semiconductors for signal processing. Typically, a silicon substrate is used in conjunction with various metal compounds to make up the raw material; this is known as a wafer. The etching process leaves metal areas which are used for electrical conduction and oxide regions which are used for insulation.

CMOS technology is used throughout today's FPA cameras. Most importantly, however, is the fact that this technology has allowed the volume manufacture of various types of IR sensitive material in array formats.

CMOS Detector

A CMOS detector has a readout that is made up of a series of MOSFET (Metal Oxide Silicon Field Effect Transistors) that provide Direct Access to the signal from each detector. In a CMOS detector, the signal from each detector is read out column by column and row by row, until each detector has been addressed individually. The benefit to this technique is that the exact value for each detector is transmitted to the signal processor for measurement.

CMOS circuits are ideal for low power applications. Power dissipation in a detector readout circuit is critical because it must be cooled with the detector to approximately -200 degrees Celsius. Even with a highly efficient cooler, each milliwatt of power dissipated by the readout requires about 25 milliWatts of battery power for cooling. Optimum battery life is achieved by the use of a CMOS multiplexer detector readout and high efficiency rotary Stirling cooler.

CMOS detectors are generally thought to provide better accuracy for measurements as a result of their direct access readout capability. P/PM users who require high measurement accuracy and long battery life can benefit from this technology.

Diffractive Lenses

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The use of Diffractive Lenses is a relatively new technology associated with modern FPA systems. Diffractive lenses provide the color correction capability of a set of multiple lenses with a single diffractive element.

By doing the work of several lens elements with only a single element, the size, weight and transmission of a lens can be improved. Diffractive lenses can be distinguished from standard lenses by noting the "rings" which are etched in the surface of the lens. These diffractive grooves cause lightwaves to be bent in a unique manner, thus correcting for chromatic aberration.

The use of diffractive lenses, provide P/PM users with FPA cameras which produce crisp images while minimizing the size weight and cost of the optics.

FPA (Focal Plane Array)

The first, and most widely used term to come with this new technology is the term Focal Plane Array, which describes the technology itself. A Focal Plane Array (FPA) detector is considered to be any detector which has more than one row of detectors and one line of detectors together. For example, the smallest conceivable FPA detector would have a configuration of 2 x 2 detectors (two rows and two columns). This configuration is basically described by the term Array. The term Focal Plane refers actually to the location of the detector array in the optical path. The Focal Plane of an optical system is a point at which the image is focused. Thus, in a FPA system, you have an array of detectors at a point where the image is focused on them. Most typical IR FPA systems available today have an array of 256 x 256 detectors or more (256 columns and 256 rows).

FPA detectors bring high resolution IR imaging capabilities into the P/PM users' hands. By having an array of detectors "staring" at the scene rather than a single detector being scanned across the scene, IR cameras have become much smaller, lighter and more power efficient. Today's modern IR FPA systems have the portability of video palmcorders and the imaging quality of black and white TV cameras.

Fill Factor

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In a Focal Plane Array, not all of the surface of the detector is sensitive to IR energy. Since the array is made up of rows and columns of individual IR detectors, there is an inactive region surrounding each detector forming the rows and columns. You can think of this like a matrix of corn fields with roads running around them. Corn is grown in the fields, but not on the roads providing transportation from field to field. The inactive area between the rows and columns of an IR FPA are pathways for electronic signals. The ratio of active IR sensing material on an FPA to inactive row and column borders is called the Fill Factor. An ideal detector would have a very high fill factor, since it would have a large majority of its area dedicated to collecting IR photons and a very small area dedicated to detector segregation. Today's best IR FPA detectors offer fill factors as high as 90%.

Fill factor can be an important parameter to the average P/PM user. A camera with a high fill factor detector will typically provide better sensitivity and overall image quality than one with a lower fill factor. Also, high fill factor detectors typically offer better cooling efficiency, so less power is utilized cooling the detector down to operating temperature. This translates into longer battery life and greater cooler reliability.

Hybrid FPA

The other common type of FPA is a Hybrid Array. A Hybrid array is an array where the IR sensitive detector material is on one layer and the signal transmission and processing circuitry is on another layer. You can compare this to a city where the buildings are on one layer and the public transportation is on a subway underneath. In a Hybrid FPA, the two layers are bonded together by small Indium "bumps" which transmit the signal from each detector element to its respective signal path on the multiplexer below, much like a staircase joins the subway to the street level.

This process is known as "Indium Bump Bonding." Although this process requires more steps and can be more expensive, it results in FPAs with significantly higher fill factor (~75-90%). The higher fill factor resulting from this geometry provides much higher sensitivity than typically found in corresponding Monolithic FPAs.

The greatest benefit provided by Hybrid FPAs to the P/PM user comes in the form of high thermal sensitivity. This results from the Hybrid FPA's relatively high fill factor. Some FPA cameras employing this technology provide sensitivity down to 0.02 degrees Celsius (32 degrees Fahrenheit). Very high sensitivity can be useful in NDT applications, air in-leakage surveys and building diagnostic studies.

Indium Antimonide (InSb) FPA

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Indium Antimonide (InSb) is a detector material that was very common in single detector, mechanically scanned units from the past. The material typically offers higher sensitivity as a result of its very high quantum efficiency (80-90%). The high quantum efficiency does not buy you as much as it may seem however. Most IR manufacturers design their systems so that the detector wells are filled at about the 80 degrees Celsius on Range 1. With PtSi, this means allowing the detector to collect photons for most of the available 1/60th of a second time frame. With InSb, the wells fill in a few microseconds and after that you have to dump the rest of the photons. As a result, for most applications there is little benefit to the added quantum efficiency.

Another drawback to InSb FPAs for general applications is their relative instability over time. InSb IR FPAs have been found to drift in their non-uniformity characteristics over time, and from cooldown to cooldown, thus requiring "Two Point Non Uniformity Corrections" in the field periodically. This can be done, but typically makes the system more complex by including mechanical shutters, thermoelectric coolers and additional electronics in the camera. For this reason, few manufacturers utilize InSb FPA detectors for measurement applications.

The added complexity of an InSb system is generally warranted in applications where extreme thermal sensitivity is required. Examples include such applications as long range military imaging.

Microbolometer FPA

An emerging technology which will also be incorporated into P/PM IR FPA devices is that of Microbolometer Detectors. These detectors are different than the previous detectors that have been reviewed in that a Microbolometer detector is a Thermal detector rather than a Photon counter. A microbolometer detector actually heats up as a result of being exposed to IR energy. As the microbolometer detector heats up, its electrical resistance changes proportionally. This resistance can be measured by applying a bias current to the detector.

Microbolometer detectors offer several promising benefits to the P/PM user. Of most significance, is that a Microbolometer will operate at near room temperature. This means that cryogenic cooling devices could be eliminated which should lower costs and increase reliability. Also, Microbolometer based cameras will operate in the longwave region, which will be useful in outdoor and low temperature applications.

Microbolometer detectors do have some drawbacks. At this time, no one is manufacturing these detectors in production quantities due to the lack of experience in the process, which makes them not practical for use in commercial cameras today. Also, Microbolometer detectors will be less sensitive and produce poorer quality images than their cooled counterparts. Lastly, microbolometer detectors are less likely to produce the accuracy and stability that P/PM users have become accustomed to with cooled sensors. This is due to the fact that a very small change in output reading with these detectors.

In any case, this technology is likely to lower the costs of IR cameras somewhat and will provide users with cameras that are truly "solid state" with no moving parts.

Monolithic FPA

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Today, there are basically two types of IR FPAs: monolithic and hybrid. Monolithic FPAs have both the IR sensitive material and the signal transmission paths on the same layer. You can think of this like a city that has both buildings and transportation all on the surface of the land. Monolithic FPAs have the benefit of typically being easier and less expensive to manufacture, since fewer steps are required in the process. On the other hand, Monolithic FPAs are typically considered to have lower performance than their Hybrid counterparts because they have a significantly lower fill factor (~55%). Monolithic FPAs have a lower fill factor because both the IR sensitive detector material and signal pathways are on the same level.

Most P/PM users will see the difference between a system with a Monolithic FPA array and a Hybrid array manifested in image quality. Systems with Monolithic arrays typically have less sensitivity than those utilizing a Hybrid array and as a result may have a poorer quality image. This is particularly noticeable when viewing low temperatures or scenes with small temperature differences. Also, until recently, advanced features such as variable integration time have not been found in Monolithic array designs due to the lack of flexibility with this design approach. This would mean that optical filters would be required to achieve high temperature imaging versus utilizing electronic signal attenuation methods which can be done with arrays having variable integration timing.

Multiplexer

A Multiplexer is the device that organizes and formats the signals from each detector in a repeatable fashion. Typically, a multiplexer takes the output from the 65,000 or more detectors and feeds them to one or more outputs. The way that the signal is taken from each detector and sent to the signal processor is determined by the detector Readout type.

Non-Reimaging Lens Design

A Non-Reimaging Lens Design is a lens that has the IR image focused at only one point in the optical path. This single point of focus is on the FPA detector itself. This type of lens design does not have any elements designed for absorbing off axis stray radiation. These lenses are used widely in imaging only FPA products since the effects of stray radiation are of little concern in non measurement devices. A benefit to this type of design is a reduction in lens size and weight. Typically non-reimaging lenses have fewer elements and are less expensive to manufacture than their reimaging counterparts.

P/PM users can use systems with non-reimaging lenses in non measurement applications. When using this type of system in measurement scenarios, the user should be aware of external sources of IR energy in the survey environment and how they can change the resulting image and measurement data obtained with the camera.

Nonuniformity Correction

One of the less desirable characteristics of modern FPA detectors is their relative nonuniformity from detector to detector. This results from variations in the manufacturing process and the detector material itself. The fact remains that all FPA detectors are fairly nonuniform in their response to temperature when they are built. To correct for this, virtually all FPA cameras have some type of nonuniformity correction built into the camera. Methods for correcting this problem vary greatly from manufacturer to manufacturer. The most simple approach is when a lens cap is placed on the camera and a "NUC" button is depressed and the camera corrects for uniformity based on the temperature of the lens cap. Other systems have a uniform temperature "paddle" within the camera which is inserted in the optical path periodically to correct the detector. Some systems have permanent multi-point nonuniformity correction in the field. This appears to be the best approach since it requires no user intervention and also provides for nonuniformity correction at several temperatures and not just at the lens cap temperature as with other approaches.

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Nonuniformity correction is an important parameter for the P/PM user to consider given that it needs to be done each time you change ranges, lenses, or when the camera operating temperature varies. Systems that do this automatically will prove to be the easiest to use in the field. The best nonuniformity correction will be accomplished at a temperature as close to the object temperature as possible. For example, when looking inside a furnace at 1300 degrees Fahrenheit (704 degrees Celsius), a nonuniformity correction on the lens cap at 75 degrees Fahrenheit (24 degrees Celsius) is of little value. The best approach in this case, is to have a nonuniformity correction point that would "equalize" the array at a temperature around 1300 degrees Fahrenheit. Today, this can only be accomplished with systems that feature permanent multi-point nonuniformity correction.

Platinum Silicide (PtSi) FPA

Platinum Silicide (PtSi) is today's most common FPA detector material. The reason for this is that PtSi operates in the shortwave region (1-5um), has good sensitivity (as low as 0.05 degrees Celsius) and has excellent stability. PtSi is also used because it is manufacturable using semiconductor production techniques with fairly high detector yields resulting in reasonable costs.

PtSi detectors have been desirable for measurement cameras since it is a highly stable material that resists drift over time in its responsivity to temperature. PtSi FPA detectors have been fielded for more than 10 years now, and have an extremely well proven reliability and long term stability record. One drawback to PtSi as a detector material is its low quantum efficiency of <1%, However, modern signal processing techniques coupled with Hybrid construction and CMOS readouts have made PtSi into a leading material for use in P/PM and scientific IR imaging environments.

PtSi is a good detector material choice for general purpose P/PM applications. The detector offers a good mix of sensitivity, accuracy and stability to meet most IR imaging needs.

Quantum Efficiency

Quantum Efficiency can be thought of as "Collection Efficiency." Most IR detectors are photon counters, they count IR photons over very short periods of time. Quantum Efficiency refers to the relative efficiency at which IR photons are collected and converted into electrical charges. A high quantum efficiency is a good thing to have since it makes signal processing easier. Surprisingly, the most popular IR FPA detector material today, Platinum Silicide (PtSi) has a very low quantum efficiency (less than 1%).

Although, Quantum Efficiency is only one measure of a system's design, it is a good way to evaluate the overall sensitivity of an IR detector. IR FPAs with high quantum efficiency typically offer better sensitivity and performance at low temperatures.

Quantum Well (QWIP) FPA

A relatively new FPA detector available is Quantum Well Infrared Photodetector (QWIP). Due to the unique bandgap of this material, these detectors operate in the long wavelength region (9-10um). QWIP detectors have a quantum efficiency of 5-10% at 9.5 um and offer very high thermal sensitivity (0.015 degrees Celsius)(32 degrees Fahrenheit).

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At this point, this technology is relatively unproven and immature. One question yet to be answered is the long term stability and uniformity of this material. Another drawback to these detectors is the requirement for cooling the detector to -65 degrees Kelvin (-208 degrees Celsius)(-342 degrees Fahrenheit), which puts an added load on the cooling device inside the camera.

Assuming that the technical concerns can be addressed, QWIP detectors could benefit the P/PM user by providing a FPA camera with very good imaging and measurement performance while operating in the longwave region. These units could be useful in outdoor applications where solar reflections are a problem or in applications where very low ambient temperatures are a factor.

Reimaging Lens Design

There are two types of lens designs currently in use with modern FPA systems: Reimaging and Non-Reimaging. A Reimaging lens is one that has the image in focus at two points within the optical path. One point is on the detector (as with all lenses) and the second point is in the middle of the lens at a point called an intermediate focal plane. This point in the middle of the lens, where the image is refocused, is used for placing a device in the optical path which will capture energy from objects outside of the normal field of view (referred to as off-axis stray radiation).

The device that is placed at the intermediate focal plane is called a Field Stop. The field stop has an opening in it which corresponds to the field of view of the lens. This is an important feature, since without this capability imaging and measurement data can be corrupted by hot or cold objects that reside outside the field of view of a camera's lens.

P/PM users who are using IR FPA cameras for measurement purposes in industrial environments should be aware of this design factor. Systems with Reimaging lenses can be used in environments where there are a variety of hot and cold objects around the object that is being measured. Systems that do not have this type of lens design can be subject to measurement errors as a result of off-axis stray energy falling on the FPA detector.

Variable Integration Time

Variable Integration Time (VIT) refers to a characteristic of the acquisition control of a FPA. The Integration Time is the period of time that the FPA is allowed to collect IR photons. Typically, an FPA runs at a maximum integration time of 16 milliseconds, which is one complete frame.

Arrays that have Variable Integration Time have the capability of capturing photons over shorter periods of time. This reduces the amount of energy that the detector captures at any given temperature. A common use for FPAs with VIT is to have high temperature imaging and measurement capabilities without needing filters. Some modern FPAs will operate up to 450 degrees Celsius (842 degrees Fahrenheit) simply by using VIT.

For the P/PM user, having a FPA with Variable Integration Timing is a time saver since one can view higher temperatures by changing the electrical characteristics of the detector rather than installing an optical filter. Systems without adequate VIT typically require several filters to cover a span of -10 degrees Celsius(14 degrees Fahrenheit) to 1500 degrees Celsius(2732 degrees Fahrenheit).

Return to Infrared Thermography Reference Articles Index

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Reliability Tips Proposed A B Maintenance Proposed C D E F G,I K,L M N,O P R S T,U V,W Definitions Discussion Maintenance Forum Definitions Employment Downloads Word of Phrase Definition Newsletter Actuarial analysis Statistical calculation, especially of life expectancy Useful Links Add-on work Work added to a maintenance schedule after the agreed upon cut-off

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Action results Indicator Key Performance Indicators used for measuring results of actions that indirectly or directly impacts the financial performance of the company. Examples

Apprentice An employee in a certified training program to become a craftsperson. Asset An accounting term for any physical thing owned by a plant, such as

buildings, equipment, desks, software, computers etc. Asset number A number that follows a particular asset in a plant, should be used for accounting purposes. Note an asset number is different from an

equipment location number. An equipment location number stays in the same location, where an asset number may move location. Asset Replacement The current accounting value of all combined physical assets in a

Value plant. Assessment - reliability A study comparing the Current best Practices (CBP) with actual performance. The study assesses the effectiveness of processes in place. Autonomous Maintenance processes driven by hourly workforce without

Maintenance management support or intervention. Autonomous Training Training that is incorporated into the day-to-day work processes. The training is based on experiences and findings from the daily work and is then communicated on a regular basis. Availability Percentage of total hours (8760/year) or scheduled operating time a

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› Reliability Articles Chronic Failure

› Reliability Links A frequently occurring, low impact event that demands attention, but takes little time to restore, and almost never has a $ figure calculated for the total loss. The total losses from chronic failures far exceed the total losses Newsletter from sporadic failures over the life of a system. › Subscribe

Condition Based Maintenance Reliability Forums › Post, Respond or Read Scheduled inspections, predictive NDT, tests, and measurements to determine whether an item is in, and will remain in, a satisfactory condition until time for the next scheduled Search inspection.

Critical Success Factor

A specific, measurable key result that indicates a mission has been successful. No more that eight CSF's should be identified in order to focus on the most important key result areas.

- D -

Data Fragility

The measure of how quickly data can become distorted or disappear all together.

Defect

A characteristic which does not conform to applicable specification requirements and which adversely affects the quality of service.

Determinism

Reaction to the environment or to stimuli. Ex: oil and metal filings will cause bearing damage, a loud sharp noise will cause people to turn their head in the direction of the noise.

Discoverability

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The answer to a question begs another question.

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Error/Change Phenomenon

Natures protection against catastrophic random events caused by the human being.

- F -

Failure

Any event that impacts a system in a way that adversely affects the system criteria. For example, the criteria could include output in a sold-out condition, or maintenance cost or capital resources in a constrained budget cycle, environmental excursions or safety, etc. A failure definition should contain specific criteria and not be ambiguous. Failure definition can change on a given system over time.

Failure Mode

A particular way in which failures occur, independent of the reason for failure.

Failure Modes and Effects Analysis (FMEA)

A modified methodology to identify the modes of failure events and assigning values to them based on unit cost and frequency, then prioritizing the result in order to focus the organization on the significant few failures.

Failure Rate

The number of failures of an item per unit measurement of life. Failure rate is considered constant over the useful life period.

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GAP

Difference between what is possible to produce and what is actually being produced

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Homicide Preservation Strategy

Data collection strategy utilized when a sporadic failure occurs.

Human Root Cause

The point of inappropriate human intervention

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Inference

The result of an individual's own logic system which has some basic flaws. Ex: wear can be expected in an abrasive environment (but what about corrosion.)

Infant Mortality

The high conditional probability of failure due to manufacturing defects, design, installation, or startup procedures during the period immediately after an item enters service.

Intuition

The repository for all of our life experiences.

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Latent Root Cause

The lack of, or deficiency in, management systems (rules, procedures, guidelines, etc.) or restraining cultural norms that allowed the

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failure to occur.

Life Cycle Cost (LCC)

Total cost of a system from conception to demolition.

Logic Tree

A pictorial method to guide logic to solve problems.

- M -

Maintainability

A measure of the ease and rapidity with which a system can be restored to operational status following a failure.

Mean Time Between Failures (MTBF)

Total operating time divided by the number of failures. MTBF is the inverse of failure rate.

Mean Time To Restore (MTTR)

Total elapsed time from initial failure to the reinitiating of system status. Mean Time To Restore includes Mean Time To Repair (MTBF + MTTR = 1.)

Mission

Defines the purpose of the analysis effort.

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- O -

Observation Blocks

Details what is observed when failure occurs.

Opportunity

Circumstance which allows you a way to improve the status quo.

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Order

The definiteness of nature; Ex: spring follows winter, night follows day.

"Out of the Box" Thinking

Going beyond conventional wisdom when trying to understand a failure.

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Paradigm

A mind-set that is universally shared by a majority of the population.

Paradigm Shift

The process of changing mind-sets to accommodate new realities.

Pareto Split

A few items within a collection of items are more significant than are the remaining majority. Also known as the 80/20 rule.

Perception

What we think we sense.

Physical Root Cause

The cause or causes that involve tangible materials.

Precision

Defines the culture of an organization that does not accept failures of any type including primary failures. The next generation of operational excellence that will replace predictive systems. The effort to achieve the limit of proactivity.

Preserving Failure Data

Collecting data at the time of a failure.

Preventive Maintenance

The care and servicing by maintenance professionals for the purpose of maintaining system reliability levels. This includes scheduled downtime maintenance.

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Primary Failure

Equipment: Component defect

Process: A process variable out of acceptable limits.

Human: Restive attitudes with deficiencies in knowledge or skill.

PROACT™

A disciplined methodology used to get to the root causes of failures.

Proaction

Any activity that will improve operations, prevent mechanical, process or human failure or lessen the consequences of failure.

Problem

A deviation from the status quo or a norm.

Productivity as a Function of Reliability

Productivity = MTBF/(MTBF+MTTR)

- Q -

- R -

Random Many

The many deviations that occur in a manufacturing facility that overall have little impact on operations.

Reaction

A condition where the environment controls human action.

Reliability

The probability of component or system success under stated conditions for a stated period of time.

Root Cause Failure Analysis (RCFA)

A technique for uncovering the cause of a failure by deductive reasoning down to the physical http://www.reliability.com/glossary.htm (7 of 10) [5/15/2004 9:49:16 AM] Reliability Center, Inc. - Glossary of Terms

and human root(s), and then using inductive reasoning to uncover the much broader latent or organizational root(s.)

- S -

Secondary Failure

Equipment: Equipment failure

Process: Poor quality product or poor yields

Human: Withdrawal of ability to add value to work

Significant Few

The few work items that have the biggest impact on plant activity.

Sporadic Failure

An infrequent, dramatic, time consuming, high impact event, demanding urgent attention, and almost always generating a high $ cost.

Stakeout & Homicide Preservation Strategy

Data collection strategies utilized when analyzing a chronic failure

- T -

Top Block

The definition of the problem.

Top Box

Contains both the Top Block and Observation Blocks.

- U -

- V -

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Wearout

The process of attrition which results in an increase in the probability of failure rate with increasing age (time, cycles, events, etc.)

Witch Hunt

The real or perceived need for management to blame someone for system failures.

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http://www.reliability.com/glossary.htm (10 of 10) [5/15/2004 9:49:16 AM] * A Vibration Institute's Glossary Page - A to E Vibration Terminology The Vibration Institute has set a goal of developing a comprehensive glossary of vibration terminology. The following list of words and definitions is very definitely "under construction," and we need your input to continue the progress toward our objective.

INSTRUCTIONS: There is open dialog for each word. You can review the current definition and either give the word a thumbs up, or if you feel there is room for improvement, give the word a thumbs down and share your constructive thoughts. All of the feedback (positive and negative) will be reviewed, and the definition will be updated periodically to a new and revised form. Your help in refining these definitions is appreciated.

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

Accelerance The frequency response function of acceleration/force. Also known as inertance.

Accelerometer A transducer whose output is n electrical/mechanical directly proportional to acceleration forces. The output is usually produced by force applied to a piezoelectric crystal which generates a current proportional to the applied force. This current is then amplified and displayed as a time waveform or processed by a Fourier transform to produce a frequency display. Single integration of the acceleration signal will produce a velocity display and double integration of the acceleration signal will produce a displacement display.

Accuracy How close a measurement is to the absolute quantity.

Acoustic Emission

http://www.vibinst.org/vglos_a-e.htm (1 of 19) [5/15/2004 9:49:36 AM] * A Vibration Institute's Glossary Page - A to E The detected energy that is generated when materials are deformed or break. For rolling element bearing analysis, it is the periodic energy generated by the over rolling of particles or flaws and detected by the display of the bearing flaw frequencies.

Algorithm A specific procedure for solving mathematical problems. An FFT is an algorithm.

Aliasing To digitize an analog signal for processing in digital instruments such as an FFT analyzer, it first must be periodically sampled, the sampling process occurring at a specific rate called the sampling frequency. As long as the sampling frequency is more than twice as high as the highest frequency in the signal, the sampled wave will be a proper representation of the analog waveform. If, however, the sampling frequency is less than twice as high as the highest frequency to be sampled, the sampled waveform will contain extraneous components called "aliases." The generation of aliases is called aliasing.

An example of aliasing sometimes occurs in motion pictures, as for instance when the wagon wheels in a Western seem to be going backward. This is optical aliasing, caused by the fact that the frame rate of the movie camera (24 frames per second) is not fast enough to resolve the positions of the spokes. Another example of optical aliasing is the stroboscope, where a moving object is illuminated by a flashing light and can be made to appear stationary, or move backward.

Aliasing must be avoided in digital signal analysis to prevent errors, and FFT analyzers always contain low pass filters in their input stages to eliminate frequency components higher than one-half the sampling frequency. These filters are automatically tuned to the proper values as the sampling frequency is changed, and this occurs when the frequency range of the analyzer is changed. http://www.vibinst.org/vglos_a-e.htm (2 of 19) [5/15/2004 9:49:36 AM] * A Vibration Institute's Glossary Page - A to E

Alignment A condition whereby the axes of machine components are either coincident, parallel or perpendicular, according to design requirements, during operation.

Amplification Factor (Q) The amount of mechanical gain of a structure when excited at a resonant frequency. The ratio of the amplitude of the steady state solution (amplitude at resonance) to the static deflection for the same force F. The amplification factor is a function of the system damping. For a damping ratio =0 (no damping) the amplification factor is infinite, for =1 (critically damped) there is no amplification.

Amplitude The measurement of energy or movement in a vibrating object. Amplitude is measured and expressed in three ways: Displacement (commonly in mils Pk-Pk); Velocity (commonly in In/Sec Pk); and Acceleration (commonly in gs RMS). Amplitude is also the y-axis of the vibration time waveform and spectrum, it helps define the severity of the vibration.

Analog Quantities in two separate physical systems having consistently similar relationships to each other are called analogous. One is then called the analog of the other. The electrical output of a transducer is an analog of the vibration input of the transducer as long as the transducer is not operated in the nonlinear (overloaded) range. This is in contrast to a digital representation of the vibration signal, which is a sampled and quantisized signal consisting of a series of numbers, usually in binary notation.

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Analog to Digital Conversion The process of sampling an analog signal produces a series of numbers which is the digital representation of the same signal. The sampling frequency must be at least twice as high as the highest frequency present in the signal to prevent aliasing errors.

Angularity The angle between two shaft center lines; this angle is the same at any point along either centerline. It is normally specified in rise/run.

Anti-Aliasing Filter The low pass filter in the input circuitry of digital signal processing equipment such as FFT analyzers which eliminates all signal components higher in frequency than one-half the sampling frequency. See Aliasing.

Apodize, Apodization To apodize is to remove or smooth a sharp discontinuity in a mathematical function, an electrical signal or a mechanical structure. An example would be to use a Hanning Window in the FFT analyzer to smooth the discontinuities at the beginning and end of the sample time record.

Asymmetrical Support A rotor support system that does not provide uniform restraint in all radial directions. This is typical in industrial machinery where stiffness in one plane may be substantially different than stiffness in the perpendicular plane. Occurs in bearings by design, or from preloads such as gravity or misalignment.

Asynchronous

http://www.vibinst.org/vglos_a-e.htm (4 of 19) [5/15/2004 9:49:36 AM] * A Vibration Institute's Glossary Page - A to E Nonsynchronous Frequencies in a vibration spectrum that exceed shaft turning speed (TS), but are not integer or harmonic multiples of TS. Also commonly refered to as non-synchronous.

Attitude Angle The angle between the steady state preload through the bearing centerline, and a line drawn between the bearing center and the shaft centerline. (Applies to fluid film bearings).

Auto Correlation Auto correlation is a time-domain function that is a measure of how much a signal shape, or waveform, resembles a delayed version of itself. It is closely related to the Cepstrum, q.v. The numerical value of auto correlation can vary between zero and one. A periodic signal, such as a sine wave has an auto correlation that is equal to one at zero time delay, zero at a time delay of one-half the period of the wave, and one at a time delay of one period; in other words, it is a sinusoidal waveform itself. Random noise has an auto correlation of one at zero delay, but is essentially zero at all other delays. Auto correlation is sometimes used to extract periodic signals from noise. Certain dual-channel FFT analyzers are able to measure auto correlation.

Averaging In performing spectrum analysis, regardless of how it is done, some form of time averaging must be done to accurately determine the level of the signal at each frequency. In vibration analysis, the most important type of averaging employed is linear spectrum averaging, where a series of individual spectra are added together and the sum is divided by the number of spectra.

Averaging is very important when performing spectrum analysis of any signal that changes with time, and this is usually the case with vibration signals of machinery. Linear

http://www.vibinst.org/vglos_a-e.htm (5 of 19) [5/15/2004 9:49:36 AM] * A Vibration Institute's Glossary Page - A to E averaging smoothes out the spectrum of the random noise in a spectrum making the discrete frequency components easier to see, but it does not actually reduce the noise level.

Another type of averaging that is important in machinery monitoring is time domain averaging, or time synchronous averaging, and it requires a tachometer connected to the trigger input of the analyzer to synchronize each "snapshot" of the signal to the running speed of the machine. Time domain averaging is very useful in reducing the random noise components in a spectrum, or in reducing the effect of other interfering signals such as components from another nearby machine.

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An Introduction to Total Productive Maintenance (TPM)

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Home Articles Webstore Jobs Software Tools Links Search About An Introduction to Total Productive Maintenance (TPM)

By Venkatesh J

What is Total Productive Maintenance ( TPM ) ?

It can be considered as the medical science of machines. Total Productive Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment. The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction.

TPM brings maintenance into focus as a necessary and vitally important part of the business. It is no longer regarded as a non-profit activity. Down time for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process. The goal is to hold emergency and unscheduled maintenance to a minimum.

Why TPM ?

TPM was introduced to achieve the following objectives. The important ones are listed below.

● Avoid wastage in a quickly changing economic environment.

● Producing goods without reducing product quality.

● Reduce cost.

● Produce a low batch quantity at the earliest possible time.

● Goods send to the customers must be non defective.

Similarities and differences between TQM and TPM :

The TPM program closely resembles the popular Total Quality Management (TQM) program. Many

http://www.plant-maintenance.com/articles/tpm_intro.shtml (1 of 20) [5/15/2004 9:54:09 AM] An Introduction to Total Productive Maintenance (TPM) of the tools such as employee empowerment, benchmarking, documentation, etc. used in TQM are used to implement and optimize TPM.Following are the similarities between the two.

1. Total commitment to the program by upper level management is required in both programmes 2. Employees must be empowered to initiate corrective action, and 3. A long range outlook must be accepted as TPM may take a year or more to implement and is an on-going process. Changes in employee mind-set toward their job responsibilities must take place as well.

The differences between TQM and TPM is summarized below.

Category TQM TPM

Object Quality ( Output and effects ) Equipment ( Input and cause )

Systematize the management. It is Employees participation and it Mains of attaining goal software oriented is hardware oriented

Elimination of losses and Target Quality for PPM wastes.

Types of maintenance :

1. Breakdown maintenance :

It means that people waits until equipment fails and repair it. Such a thing could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost.

2. Preventive maintenance ( 1951 ):

It is a daily maintenance ( cleaning, inspection, oiling and re-tightening ), design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis, to measure deterioration. It is further divided into periodic maintenance and predictive maintenance. Just like human life is extended by preventive medicine, the equipment service life can be prolonged by doing preventive maintenance.

2a. Periodic maintenance ( Time based maintenance - TBM) :

Time based maintenance consists of periodically inspecting, servicing and cleaning equipment and replacing parts to prevent sudden failure and process problems.

http://www.plant-maintenance.com/articles/tpm_intro.shtml (2 of 20) [5/15/2004 9:54:09 AM] An Introduction to Total Productive Maintenance (TPM) 2b. Predictive maintenance :

This is a method in which the service life of important part is predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. Compared to periodic maintenance, predictive maintenance is condition based maintenance. It manages trend values, by measuring and analyzing data about deterioration and employs a surveillance system, designed to monitor conditions through an on-line system.

3. Corrective maintenance ( 1957 ) :

It improves equipment and its components so that preventive maintenance can be carried out reliably. Equipment with design weakness must be redesigned to improve reliability or improving maintainability

4. Maintenance prevention ( 1960 ):

It indicates the design of a new equipment. Weakness of current machines are sufficiently studied ( on site information leading to failure prevention, easier maintenance and prevents of defects, safety and ease of manufacturing ) and are incorporated before commissioning a new equipment.

TPM - History:

TPM is a innovative Japanese concept. The origin of TPM can be traced back to 1951 when preventive maintenance was introduced in Japan. However the concept of preventive maintenance was taken from USA. Nippondenso was the first company to introduce plant wide preventive maintenance in 1960. Preventive maintenance is the concept wherein, operators produced goods using machines and the maintenance group was dedicated with work of maintaining those machines, however with the automation of Nippondenso, maintenance became a problem as more maintenance personnel were required. So the management decided that the routine maintenance of equipment would be carried out by the operators. ( This is Autonomous maintenance, one of the features of TPM ). Maintenance group took up only essential maintenance works.

Thus Nippondenso which already followed preventive maintenance also added Autonomous maintenance done by production operators. The maintenance crew went in the equipment modification for improving reliability. The modifications were made or incorporated in new equipment. This lead to maintenance prevention. Thus preventive maintenance along with Maintenance prevention and Maintainability Improvement gave birth to Productive maintenance. The aim of productive maintenance was to maximize plant and equipment effectiveness to achieve optimum life cycle cost of production equipment.

By then Nippon Denso had made quality circles, involving the employees participation. Thus all employees took part in implementing Productive maintenance. Based on these developments Nippondenso was awarded the distinguished plant prize for developing and implementing TPM, by the Japanese Institute of Plant Engineers ( JIPE ). Thus Nippondenso of the Toyota group became http://www.plant-maintenance.com/articles/tpm_intro.shtml (3 of 20) [5/15/2004 9:54:09 AM] An Introduction to Total Productive Maintenance (TPM) the first company to obtain the TPM certification.

TPM Targets:

P Obtain Minimum 80% OPE. Obtain Minimum 90% OEE ( Overall Equipment Effectiveness ) Run the machines even during lunch. ( Lunch is for operators and not for machines ! )

Q Operate in a manner, so that there are no customer complaints.

C Reduce the manufacturing cost by 30%. D Achieve 100% success in delivering the goods as required by the customer.

S Maintain a accident free environment.

M Increase the suggestions by 3 times. Develop Multi-skilled and flexible workers.

Motives of TPM 1. Adoption of life cycle approach for improving the overall performance of production equipment. 2. Improving productivity by highly motivated workers which is achieved by job enlargement. 3. The use of voluntary small group activities for identifying the cause of failure, possible plant and equipment modifications.

Uniqueness of TPM The major difference between TPM and other concepts is that the operators are also made to involve in the maintenance process. The concept of "I ( Production operators ) Operate, You ( Maintenance department ) fix" is not followed.

TPM Objectives 1. Achieve Zero Defects, Zero Breakdown and Zero accidents in all functional areas of the organization. 2. Involve people in all levels of organization. 3. Form different teams to reduce defects and Self Maintenance.

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Direct benefits of TPM 1. Increase productivity and OPE ( Overall Plant Efficiency ) by 1.5 or 2 times. 2. Rectify customer complaints. 3. Reducethe manufacturing cost by 30%. 4. Satisfy the customers needs by 100 % ( Delivering the right quantity at the right time, in the required quality. ) 5. Reduce accidents. 6. Follow pollution control measures.

Indirect benefits of TPM 1. Higher confidence level among the employees. 2. Keep the work place clean, neat and attractive. 3. Favorablechange in the attitude of the operators. 4. Achieve goals by working as team. 5. Horizontaldeployment of a new concept in all areas of the organization. 6. Share knowledge and experience. 7. The workers get a feeling of owning the machine.

OEE ( Overall Equipment Efficiency ) :

OEE = A x PE x Q

A - Availability of the machine. Availability is proportion of time machine is actually available out of time it should be available.

A = ( MTBF – MTTR ) / MTBF.

MTBF – Mean Time Between Failures = ( Total Running Time ) / Number of Failures. MTTR – Mean Time To Repair.

PE - Performance Efficiency. It is given by RE X SE.

Rate efficiency (RE) : Actual average cycle time is slower than design cycle time because of jams, etc. Output is reduced because of jams Speed efficiency (SE) : Actual cycle time is slower than design cycle time machine output is reduced because it is running at reduced speed.

Q - Refers to quality rate. Which is percentage of good parts out of total produced sometimes called “yield”.

http://www.plant-maintenance.com/articles/tpm_intro.shtml (5 of 20) [5/15/2004 9:54:09 AM] An Introduction to Total Productive Maintenance (TPM) Steps in introduction of TPM in a organization :

Step A - PREPARATORY STAGE :

STEP 1 - Announcement by Management to all about TPM introduction in the organization :

Proper understanding, commitment and active involvement of the top management in needed for this step. Senior management should have awareness programmes, after which announcement is made to all. Publish it in the house magazine and put it in the notice board. Send a letter to all concerned individuals if required.

STEP 2 - Initial education and propaganda for TPM :

Training is to be done based on the need. Some need intensive training and some just an awareness. Take people who matters to places where TPM already successfully implemented.

STEP 3 - Setting up TPM and departmental committees :

TPM includes improvement, autonomous maintenance, quality maintenance etc., as part of it. When committees are set up it should take care of all those needs.

STEP 4 - Establishing the TPM working system and target :

Now each area is benchmarked and fix up a target for achievement.

STEP 5 - A master plan for institutionalizing :

Next step is implementation leading to institutionalizing wherein TPM becomes an organizational culture. Achieving PM award is the proof of reaching a satisfactory level.

STEP B - INTRODUCTION STAGE

This is a ceremony and we should invite all. Suppliers as they should know that we want quality supply from them. Related companies and affiliated companies who can be our customers, sisters concerns etc. Some may learn from us and some can help us and customers will get the communication from us that we care for quality output.

STAGE C - IMPLEMENTATION

In this stage eight activities are carried which are called eight pillars in the development of TPM activity. Of these four activities are for establishing the system for production efficiency, one for initial control system of new products and equipment, one for improving the efficiency of administration and are for control of safety, sanitation as working environment.

http://www.plant-maintenance.com/articles/tpm_intro.shtml (6 of 20) [5/15/2004 9:54:09 AM] An Introduction to Total Productive Maintenance (TPM) STAGE D - INSTITUTIONALISING STAGE

By all there activities one would has reached maturity stage. Now is the time for applying for PM award. Also think of challenging level to which you can take this movement.

Organization Structure for TPM Implementation :

Pillars of TPM

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PILLAR 1 - 5S :

TPM starts with 5S. Problems cannot be clearly seen when the work place is unorganized. Cleaning and organizing the workplace helps the team to uncover problems. Making problems visible is the first step of improvement.

English Equivalent 'S' Japanese Term Translation term

Seiri Organisation Sort

Seiton Tidiness Systematise

Seiso Cleaning Sweep

Seiketsu Standardisation Standardise

Shitsuke Discipline Self - Discipline

SEIRI - Sort out :

This means sorting and organizing the items as critical, important, frequently used items, useless, or

http://www.plant-maintenance.com/articles/tpm_intro.shtml (8 of 20) [5/15/2004 9:54:09 AM] An Introduction to Total Productive Maintenance (TPM) items that are not need as of now. Unwanted items can be salvaged. Critical items should be kept for use nearby and items that are not be used in near future, should be stored in some place. For this step, the worth of the item should be decided based on utility and not cost. As a result of this step, the search time is reduced.

Priority Frequency of Use How to use

Less than once per year, Once per Throw away, Store away from the Low year< workplace At least 2/6 months, Once per Average Store together but offline month, Once per week

High Once Per Day Locate at the workplace

SEITON - Organise :

The concept here is that "Each items has a place, and only one place". The items should be placed back after usage at the same place. To identify items easily, name plates and colored tags has to be used. Vertical racks can be used for this purpose, and heavy items occupy the bottom position in the racks.

SEISO - Shine the workplace :

This involves cleaning the work place free of burrs, grease, oil, waste, scrap etc. No loosely hanging wires or oil leakage from machines.

SEIKETSU - Standardization :

Employees has to discuss together and decide on standards for keeping the work place / Machines / pathways neat and clean. This standards are implemented for whole organization and are tested / Inspected randomly.

SHITSUKE - Self discipline :

Considering 5S as a way of life and bring about self-discipline among the employees of the organization. This includes wearing badges, following work procedures, punctuality, dedication to the organization etc.

PILLAR 2 - JISHU HOZEN ( Autonomous maintenance ) :

This pillar is geared towards developing operators to be able to take care of small maintenance tasks, thus freeing up the skilled maintenance people to spend time on more value added activity and technical repairs. The operators are responsible for upkeep of their equipment to prevent it from deteriorating.

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Policy :

1. Uninterrupted operation of equipments. 2. Flexible operators to operate and maintain other equipments. 3. Eliminating the defects at source through active employee participation. 4. Stepwise implementation of JH activities.

JISHU HOZEN Targets:

1. Prevent the occurrence of 1A / 1B because of JH. 2. Reduce oil consumption by 50% 3. Reduce process time by 50% 4. Increase use of JH by 50%

Steps in JISHU HOZEN :

1. Preparation of employees. 2. Initial cleanup of machines. 3. Take counter measures 4. Fix tentative JH standards 5. General inspection 6. Autonomous inspection 7. Standardization and 8. Autonomous management.

Each of the above mentioned steps is discussed in detail below.

1. Train the Employees : Educate the employees about TPM, Its advantages, JH advantages and Steps in JH. Educate the employees about abnormalities in equipments. 2. Initial cleanup of machines : ❍ Supervisor and technician should discuss and set a date for implementing step1

❍ Arrange all items needed for cleaning

❍ On the arranged date, employees should clean the equipment completely with the help of maintenance department.

❍ Dust, stains, oils and grease has to be removed.

❍ Following are the things that has to be taken care while cleaning. They are Oil leakage, loose wires, unfastened nits and bolts and worn out parts.

❍ After clean up problems are categorized and suitably tagged. White tags is place where problems can be solved by operators. Pink tag is placed where the aid of maintenance department is needed.

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❍ Make note of area which were inaccessible.

❍ Finally close the open parts of the machine and run the machine. 3. Counter Measures : ❍ Inaccessible regions had to be reached easily. E.g. If there are many screw to open a fly wheel door, hinge door can be used. Instead of opening a door for inspecting the machine, acrylic sheets can be used.

❍ To prevent work out of machine parts necessary action must be taken.

❍ Machine parts should be modified to prevent accumulation of dirt and dust. 4. Tentative Standard : ❍ JH schedule has to be made and followed strictly.

❍ Schedule should be made regarding cleaning, inspection and lubrication and it also should include details like when, what and how. 5. General Inspection : ❍ The employees are trained in disciplines like Pneumatics, electrical, hydraulics, lubricant and coolant, drives, bolts, nuts and Safety.

❍ This is necessary to improve the technical skills of employees and to use inspection manuals correctly.

❍ After acquiring this new knowledge the employees should share this with others.

❍ By acquiring this new technical knowledge, the operators are now well aware of machine parts. 6. Autonomous Inspection : ❍ New methods of cleaning and lubricating are used.

❍ Each employee prepares his own autonomous chart / schedule in consultation with supervisor.

❍ Parts which have never given any problem or part which don't need any inspection are removed from list permanently based on experience.

❍ Including good quality machine parts. This avoid defects due to poor JH.

❍ Inspection that is made in preventive maintenance is included in JH.

❍ The frequency of cleanup and inspection is reduced based on experience. 7. Standardization : ❍ Upto the previous stem only the machinery / equipment was the concentration. However in this step the surroundings of machinery are organized. Necessary items should be organized, such that there is no searching and searching time is reduced.

❍ Work environment is modified such that there is no difficulty in getting any item.

❍ Everybody should follow the work instructions strictly.

❍ Necessary spares for equipments is planned and procured. 8. Autonomous Management : ❍ OEE and OPE and other TPM targets must be achieved by continuous improve through Kaizen.

❍ PDCA ( Plan, Do, Check and Act ) cycle must be implemented for Kaizen.

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PILLAR 3 - KAIZEN :

"Kai" means change, and "Zen" means good ( for the better ). Basically kaizen is for small improvements, but carried out on a continual basis and involve all people in the organization. Kaizen is opposite to big spectacular innovations. Kaizen requires no or little investment. The principle behind is that "a very large number of small improvements are move effective in an organizational environment than a few improvements of large value. This pillar is aimed at reducing losses in the workplace that affect our efficiencies. By using a detailed and thorough procedure we eliminate losses in a systematic method using various Kaizen tools. These activities are not limited to production areas and can be implemented in administrative areas as well.

Kaizen Policy :

1. Practice concepts of zero losses in every sphere of activity. 2. relentless pursuit to achieve cost reduction targets in all resources 3. Relentless pursuit to improve over all plant equipment effectiveness. 4. Extensive use of PM analysis as a tool for eliminating losses. 5. Focus of easy handling of operators.

Kaizen Target :

Achieve and sustain zero loses with respect to minor stops, measurement and adjustments, defects and unavoidable downtimes. It also aims to achieve 30% manufacturing cost reduction.

Tools used in Kaizen :

1. PM analysis 2. Why - Why analysis 3. Summary of losses 4. Kaizen register 5. Kaizen summary sheet.

The objective of TPM is maximization of equipment effectiveness. TPM aims at maximization of machine utilization and not merely machine availability maximization. As one of the pillars of TPM activities, Kaizen pursues efficient equipment, operator and material and energy utilization, that is extremes of productivity and aims at achieving substantial effects. Kaizen activities try to thoroughly eliminate 16 major losses.

16 Major losses in a organisation: Loss Category

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1. Failure losses - Breakdown loss 2. Setup / adjustment losses 3. Cutting blade loss 4. Start up loss 5. Minor stoppage / Idling loss. Losses that impede equipment efficiency 6. Speed loss - operating at low speeds. 7. Defect / rework loss 8. Scheduled downtime loss

9. Management loss 10. Operating motion loss 11. Line organization loss 12. Logistic loss Loses that impede human work efficiency 13. Measurement and adjustment loss

14. Energy loss 15. Die, jig and tool breakage loss Loses that impede effective use of production 16. Yield loss. resources

Classification of losses : Aspect Sporadic Loss Chronic Loss

This loss cannot be easily Causes for this failure can be identified and solved. Even if Causation easily traced. Cause-effect various counter measures are relationship is simple to trace. applied This type of losses are caused Easy to establish a remedial because of hidden defects in Remedy measure machine, equipment and methods. A single cause is rare - a Impact / Loss A single loss can be costly combination of causes trends to be a rule

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Frequency of The frequency of occurrence is The frequency of loss is more. occurrence low and occasional.

Specialists in process Usually the line personnel in the engineering, quality assurance Corrective action production can attend to this and maintenance people are problem. required.

PILLAR 4 - PLANNED MAINTENANCE :

It is aimed to have trouble free machines and equipments producing defect free products for total customer satisfaction. This breaks maintenance down into 4 "families" or groups which was defined earlier.

1. Preventive Maintenance 2. Breakdown Maintenance 3. Corrective Maintenance 4. Maintenance Prevention

With Planned Maintenance we evolve our efforts from a reactive to a proactive method and use trained maintenance staff to help train the operators to better maintain their equipment.

Policy :

1. Achieve and sustain availability of machines 2. Optimum maintenance cost. 3. Reduces spares inventory. 4. Improve reliability and maintainability of machines.

Target :

1. Zero equipment failure and break down. 2. Improve reliability and maintainability by 50 % 3. Reduce maintenance cost by 20 % 4. Ensure availability of spares all the time.

Six steps in Planned maintenance :

1. Equipment evaluation and recoding present status. 2. Restore deterioration and improve weakness. 3. Building up information management system. 4. Prepare time based information system, select equipment, parts and members and map out

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plan. 5. Prepare predictive maintenance system by introducing equipment diagnostic techniques and 6. Evaluation of planned maintenance.

PILLAR 5 - QUALITY MAINTENANCE :

It is aimed towards customer delight through highest quality through defect free manufacturing. Focus is on eliminating non-conformances in a systematic manner, much like Focused Improvement. We gain understanding of what parts of the equipment affect product quality and begin to eliminate current quality concerns, then move to potential quality concerns. Transition is from reactive to proactive (Quality Control to Quality Assurance).

QM activities is to set equipment conditions that preclude quality defects, based on the basic concept of maintaining perfect equipment to maintain perfect quality of products. The condition are checked and measure in time series to very that measure values are within standard values to prevent defects. The transition of measured values is watched to predict possibilities of defects occurring and to take counter measures before hand.

Policy :

1. Defect free conditions and control of equipments. 2. QM activities to support quality assurance. 3. Focus of prevention of defects at source 4. Focus on poka-yoke. ( fool proof system ) 5. In-line detection and segregation of defects. 6. Effective implementation of operator quality assurance.

Target :

1. Achieve and sustain customer complaints at zero 2. Reduce in-process defects by 50 % 3. Reduce cost of quality by 50 %.

Data requirements :

Quality defects are classified as customer end defects and in house defects. For customer-end data, we have to get data on

1. Customer end line rejection 2. Field complaints.

In-house, data include data related to products and data related to process

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Data related to product :

1. Product wise defects 2. Severity of the defect and its contribution – major/minor 3. Location of the defect with reference to the layout 4. Magnitude and frequency of its occurrence at each stage of measurement 5. Occurrence trend in beginning and the end of each production/process/changes. (Like pattern change, ladle/furnace lining etc.) 6. Occurrence trend with respect to restoration of breakdown/modifications/periodical replacement of quality components.

Data related to processes:

1. The operating condition for individual sub-process related to men, method, material and machine. 2. The standard settings/conditions of the sub-process 3. The actual record of the settings/conditions during the defect occurrence.

PILLAR 6 - TRAINING :

It is aimed to have multi-skilled revitalized employees whose morale is high and who has eager to come to work and perform all required functions effectively and independently. Education is given to operators to upgrade their skill. It is not sufficient know only "Know-How" by they should also learn "Know-why". By experience they gain, "Know-How" to overcome a problem what to be done. This they do without knowing the root cause of the problem and why they are doing so. Hence it become necessary to train them on knowing "Know-why". The employees should be trained to achieve the four phases of skill. The goal is to create a factory full of experts. The different phase of skills are

Phase 1 : Do not know. Phase 2 : Know the theory but cannot do. Phase 3 : Can do but cannot teach Phase 4 : Can do and also teach.

Policy :

1. Focus on improvement of knowledge, skills and techniques. 2. Creating a training environment for self learning based on felt needs. 3. Training curriculum / tools /assessment etc conductive to employee revitalization 4. Training to remove employee fatigue and make work enjoyable.

Target :

1. Achieve and sustain downtime due to want men at zero on critical machines.

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2. Achieve and sustain zero losses due to lack of knowledge / skills / techniques 3. Aim for 100 % participation in suggestion scheme.

Steps in Educating and training activities :

1. Setting policies and priorities and checking present status of education and training. 2. Establish of training system for operation and maintenance skill up gradation. 3. Training the employees for upgrading the operation and maintenance skills. 4. Preparation of training calendar. 5. Kick-off of the system for training. 6. Evaluation of activities and study of future approach.

PILLAR 7 - OFFICE TPM :

Office TPM should be started after activating four other pillars of TPM (JH, KK, QM, PM). Office TPM must be followed to improve productivity, efficiency in the administrative functions and identify and eliminate losses. This includes analyzing processes and procedures towards increased office automation. Office TPM addresses twelve major losses. They are

1. Processing loss 2. Cost loss including in areas such as procurement, accounts, marketing, sales leading to high inventories 3. Communication loss 4. Idle loss 5. Set-up loss 6. Accuracy loss 7. Office equipment breakdown 8. Communication channel breakdown, telephone and fax lines 9. Time spent on retrieval of information 10. Non availability of correct on line stock status 11. Customer complaints due to logistics 12. Expenses on emergency dispatches/purchases

How to start office TPM ?

A senior person from one of the support functions e.g. Head of Finance, MIS, Purchase etc should be heading the sub-committee. Members representing all support functions and people from Production & Quality should be included in sub committee. TPM co-ordinate plans and guides the sub committee.

1. Providing awareness about office TPM to all support departments 2. Helping them to identify P, Q, C, D, S, M in each function in relation to plant performance

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3. Identify the scope for improvement in each function 4. Collect relevant data 5. Help them to solve problems in their circles 6. Make up an activity board where progress is monitored on both sides – results and actions along with Kaizens. 7. Fan out to cover all employees and circles in all functions.

Kobetsu Kaizen topics for Office TPM :

● Inventory reduction

● Lead time reduction of critical processes

● Motion & space losses

● Retrieval time reduction.

● Equalizing the work load

● Improving the office efficiency by eliminating the time loss on retrieval of information, by achieving zero breakdown of office equipment like telephone and fax lines.

Office TPM and its Benefits :

1. Involvement of all people in support functions for focusing on better plant performance 2. Better utilized work area 3. Reduce repetitive work 4. Reduced inventory levels in all parts of the supply chain 5. Reduced administrative costs 6. Reduced inventory carrying cost 7. Reduction in number of files 8. Reduction of overhead costs (to include cost of non-production/non capital equipment) 9. Productivity of people in support functions 10. Reduction in breakdown of office equipment 11. Reduction of customer complaints due to logistics 12. Reduction in expenses due to emergency dispatches/purchases 13. Reduced manpower 14. Clean and pleasant work environment.

P Q C D S M in Office TPM :

P – Production output lost due to want of material, Manpower productivity, Production output lost due to want of tools.

Q – Mistakes in preparation of cheques, bills, invoices, payroll, Customer returns/warranty attributable to

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BOPs, Rejection/rework in BOP’s/job work, Office area rework.

C – Buying cost/unit produced, Cost of logistics – inbound/outbound, Cost of carrying inventory, Cost of communication, Demurrage costs.

D – Logistics losses (Delay in loading/unloading)

● Delay in delivery due to any of the support functions

● Delay in payments to suppliers

● Delay in information

S – Safety in material handling/stores/logistics, Safety of soft and hard data.

M – Number of kaizens in office areas.

How office TPM supports plant TPM :

Office TPM supports the plant, initially in doing Jishu Hozen of the machines (after getting training of Jishu Hozen), as in Jishu Hozen at the

1. Initial stages machines are more and manpower is less, so the help of commercial departments can be taken, for this 2. Office TPM can eliminate the lodes on line for no material and logistics.

Extension of office TPM to suppliers and distributors :

This is essential, but only after we have done as much as possible internally. With suppliers it will lead to on-time delivery, improved ‘in-coming’ quality and cost reduction. With distributors it will lead to accurate demand generation, improved secondary distribution and reduction in damages during storage and handling. In any case we will have to teach them based on our experience and practice and highlight gaps in the system which affect both sides. In case of some of the larger companies, they have started to support clusters of suppliers.

PILLAR 8 - SAFETY, HEALTH AND ENVIRONMENT :

Target :

1. Zero accident, 2. Zero health damage 3. Zero fires.

In this area focus is on to create a safe workplace and a surrounding area that is not damaged by our process or procedures. This pillar will play an active role in each of the other pillars on a regular basis.

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A committee is constituted for this pillar which comprises representative of officers as well as workers. The committee is headed by Senior vice President ( Technical ). Utmost importance to Safety is given in the plant. Manager (Safety) is looking after functions related to safety. To create awareness among employees various competitions like safety slogans, Quiz, Drama, Posters, etc. related to safety can be organized at regular intervals.

Conclusion:

Today, with competition in industry at an all time high, TPM may be the only thing that stands between success and total failure for some companies. It has been proven to be a program that works. It can be adapted to work not only in industrial plants, but in construction, building maintenance, transportation, and in a variety of other situations. Employees must be educated and convinced that TPM is not just another "program of the month" and that management is totally committed to the program and the extended time frame necessary for full implementation. If everyone involved in a TPM program does his or her part, an unusually high rate of return compared to resources invested may be expected.

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Examining the Processes of RCM and TPM

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Home Articles Webstore Jobs Software Tools Links Search About Examining the Processes of RCM and TPM What do they ultimately achieve and are the two approaches compatible?

Author : Ross Kennedy

President, The Centre for TPM (Australasia)

The Background of Reliability Centred Maintenance (RCM)

RCM evolved during the 1950s in the aircraft industry as a result of a number of major reliability studies concerning complex equipment. In particular, the 1960 FAA / Airline Industry Reliability Program Study was initiated to respond to rapidly increasing maintenance costs, poor availability, and concern over the effectiveness of traditional time-based preventive maintenance. This, like several other initial studies, centred around challenging the traditional approach to scheduled maintenance programs which were based on the concept that every item on a piece of complex equipment has a ‘right age’ at which complete overhaul is necessary to ensure safety and operating reliability. Through these ‘reliability programs’ it was discovered that many types of failures could not be prevented or effectively reduced by such ‘right age’ overhauls no matter how intensively they were performed.

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Two notable and surprising findings from the 1960 FAA / Airline Industry Reliability Program were that:

❍ scheduled overhauls had little effect on the overall reliability of a complex item unless the item had a dominant failure mode; and that

❍ there were many items found for which there was no effective form of scheduled maintenance.

A New Perspective on Failure As the results of these various aircraft reliability studies unfolded, the traditional views of equipment failure as depicted by the First Generation (pre World War II), and the Second Generation (post World War II) curves were challenged. Finally, a new series of Third Generation failure curves were developed relating to specific types of equipment on aircraft (see Figure 2). Various studies have since been carried out to relate these curves to other industries.

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It became evident from the Third Generation failure patterns that views of equipment failure needed to change, as did what should be done to prevent failure. Imposed age limits and Time-Based Maintenance schedules often do little or nothing to improve the reliability of complex equipment. As shown in Figure 3, traditional maintenance can actually increase failure rates by introducing infant mortality into otherwise stable systems.

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To address these issues, maintenance was faced with four challenges:

❍ to deal effectively with each type of failure process with appropriate maintenance tactics;

❍ to improve maintenance productivity by moving towards a more pro-active and planned approach;

❍ to extend run length between scheduled shutdowns; and

❍ to ensure the active support and cooperation of people from the maintenance, material, operations and technical functions.

Reliability Centred Maintenance provides a maintenance oriented framework to meet these challenges. RCM can be defined as: a structured, logical process for developing or optimising the maintenance requirements of a physical resource in its operating context to realise its “inherent reliability" where “inherent reliability” is the level of reliability which can be achieved with an effective maintenance program. This level of reliability is a function of the equipment’s design and cannot be improved without redesign.

RCM is basically a methodology to balance the resources being used with the required

http://www.plant-maintenance.com/articles/RCMvTPM.shtml (4 of 22) [5/15/2004 9:54:53 AM] Examining the Processes of RCM and TPM inherent reliability based on the following precepts:

❍ a failure is an unsatisfactory condition and maintenance attempts to prevent such conditions from arising;

❍ the consequences of failure determine the priority of the maintenance effort;

❍ equipment redundancy should be eliminated, where appropriate;

❍ condition-based or predictive maintenance tactics are favoured over traditional time-based methods; and

❍ run-to-failure is acceptable, where warranted.

RCM Seven Step Implementation Process

RCM has seven logical review steps as shown above which are structured in an iterative process usually based on risk analysis and which depend on a clear understanding of the business objectives and requirements.

Two key tools are used in RCM: the Decision or Logic Diagram, which is called MSG-3

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The Decision Diagram is used to select maintenance tactics that are technically feasible and worth doing. Figure 4 shows a simple example of a Decision Diagram; however, in practice, a more comprehensive logic analysis is performed using more sophisticated diagrams.

Reliability Centred Maintenance has been renamed a number of times to distance it from its hi-tech origins and occasionally indicate a fresh approach - these names include RAM, RMA, R&M, MTA, MSG-3, RCM I and RCM II.

Fortunately, although the names have changed, the underlying principles of RCM have not! RCM was developed as a strategic methodology for developing a cost effective maintenance plan by identifying:

❍ what you want out of your equipment;

❍ what your equipment can do;

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❍ what you can do to ensure your equipment meets your expectations in a safe and cost-effective manner.

This is achieved using a progressive logical approach based on identifying all significant maintainable item's:

a. Function b. Functional Failure c. Failure Effects d. Failure Cause then applying a logic model to each item so as to identify tasks and maintenance inspection intervals.

It should be noted however, this approach is severely hampered if the issues of Basic Equipment Condition, Operating Standards and Accelerated Deterioration are not addressed first.

The Background to TPM Unlike RCM that emerged from the American aircraft industry, TPM had its genesis in the Japanese car industry in the 1970s. It evolved at Nippon Denso, a major supplier of the Toyota Car Company, as a necessary element of the newly developed Toyota Production System which was originally thought to only incorporate Total Quality Control (TQC), Just in Time (JIT), and Total Employee Involvement (TEI). It was not until 1988, with the publication in English of the first of two authoritative texts on the subject by Seiichi Nakajima, that the western world recognised and started to understand the importance of TPM.

Suddenly it became obvious that TPM was a critical missing link in successfully achieving not only world class equipment performance to support TQC (variation reduction) and JIT (lead time reduction), but was a powerful new means to improving overall company performance. Hence it has only been since the early 90s that TPM has started to rapidly spread throughout the western world, significantly improving the performance of manufacturing, processing, and mining companies. TPM is now having a major impact on bottom-line results by revitalising and enhancing the quality management approach to substantially improve capacity while significantly reducing not only maintenance costs but overall operational costs. Its successful implementation has also resulted in the creation of much safer and more

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The Evolution of TPM Traditionally high buffer stocks were allowed to develop between major pieces of the plant & equipment to ensure that if there was a problem with one piece of the plant or equipment then it would not affect production from the rest of the plant. Hence the role of maintenance was to cost effectively ensure major pieces of plant & equipment were available for an agreed period of scheduled time, for example 90%.

Because of the accepted practice of retaining high buffer stocks, most items of equipment could be considered independent. If the equipment in a process was maintained such that it achieved 90% availability, the availability of the process was 90%. If the equipment started to cause quality problems, these would probably be noticed in final quality inspection and the cause traced back to the offending piece of equipment and corrected by maintenance.

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At Nippon Denso in 1970 with the introduction of the Toyota Production System, the buffer stocks were substantially reduced in their quest for shorter leadtimes and improved quality. Statistical Process Control (SPC) supported by "Quality at Source" was introduced to ensure quality right first time so to provide maximum customer value through the highest quality at the lowest cost supported by quick responsiveness and superior customer service. Hence in this quest for maximum customer value, buffer stocks were reduced to both reduce leadtimes and force the identification of cost consuming problems. This resulted in individual equipment problems affecting the whole process.

If one piece of equipment stopped then shortly afterwards the whole process stopped. This made the equipment interdependent. Under these circumstances, the availability of the process became the product of the individual availabilities of each piece of equipment. Thus, a process involving four pieces of equipment maintained at 90% no longer had an overall process availability of 90%, but an availability of 90% X 90% X 90% X 90%, or 66%!

Furthermore, as the quality approach changed to "Prevention at Source" by controlling process variables, equipment performance problems were identified much earlier.

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As buffer stocks reduced substantial pressure was placed on the maintenance department to improve process performance. From a maintenance perspective, the maintenance department's performance had not deteriorated, yet demand for the substantial improvement in equipment availability was overwhelming.

This caused friction between the production and maintenance departments. Production departments demanded former levels of process availability and quicker response times from maintenance, who were often unable to comply due to traditional organisation structures which keep maintenance as a separate function. After much conflict between maintenance and production, engineering were called in to find a solution. They soon realised that mathematically for the four pieces of equipment to achieve their original goal of 90% availability, their individual availabilities needed to increase from 90% to 97.5%.

The traditional view of maintenance was to balance maintenance cost with an acceptable level of availability and reliability often influenced by the level of buffer stocks which hid the immediate impact of equipment problems. In traditional companies, maintenance is seen as an expense that can easily be reduced in relation to the overall business, particularly in the short term. Conversely, maintenance managers have always argued that to increase the level of availability and reliability of the equipment, more expenditure needs to be committed to the maintenance budget. With the on set of substantial availability problems caused by the new way of running the plant, management soon realised that just giving more resources to the maintenance department was not going to produce a cost effective solution.

This conflict between maintenance cost and availability is similar to the old quality mind-set before the advent of Total Quality Control (TQC): that higher quality required more resources, and hence cost, for final inspection and rework. TQC emphasised "prevention at source" of the problem rather than by inspection at the end of the process. Instead of enlarging the inspection department, all employees were trained and motivated to be responsible for identifying problems at the earliest possible point in the process so as to minimise rectification costs. This did not mean disbanding the quality control department but having it now concentrate on more specialist quality activities such as variation reduction through process improvement. This new approach to quality demonstrated that getting quality right first time does not cost money but actually reduces the total cost of operating the business.

This new Quality approach of "prevention at source" was translated to the

http://www.plant-maintenance.com/articles/RCMvTPM.shtml (10 of 22) [5/15/2004 9:54:53 AM] Examining the Processes of RCM and TPM maintenance environment through the concept of TPM resulting in not only superior availability, reliability and maintainability of equipment but also significant improvements in capacity with a substantial reduction in both maintenance costs and total operational costs. TPM is based on "prevention at source" and is focused on identifying and eliminating the source of equipment deterioration rather than the more traditional approach of either letting equipment fail before repairing it, or applying preventive / predictive strategies to identify and repair equipment after the deterioration has taken hold and caused the need for expensive repairs.

TPM has developed over the years since its first introduction in 1970. Originally there were 5 Activities of TPM that is now referred to as 1st Generation TPM (Total Productive Maintenance). It focused on improving equipment performance or effectiveness only. Late in the 80's it was realised that even if the shopfloor were committed fully to TPM and the elimination or minimisation of the "six big losses" there were still opportunities being lost because of poor production scheduling practices resulting in line imbalances or schedule interruptions. Hence the development of 2nd Generation TPM (Total Process Management) which focused on the whole production process.

Finally, in more recent times it has been recognised that the whole company must be involved if the full potential of the capacity gains and cost reductions are to be realised. Hence 3rd Generation TPM (Total Productive Manufacturing / Mining) has evolved which now encompasses the 8 Pillars of TPM with the focus on the 16 Major Losses incorporating the 4Ms – Man, Machine, Methods, Materials. At the CTPM we have expanded the Japanese 8 Pillars to 10 Pillars of Australasian 3rd Generation TPM to better suit our needs in Australia and new Zealand based on our extensive research of the past two and a half years.

1. Safety & Environmental Management 2. Focused Equipment & Process Improvement 3. Work Area Management 4. Operator Equipment Management 5. Maintenance Excellence for TPM 6. Education & Training 7. Human Resource Management 8. Administration & Support Systems Improvement 9. New Equipment Management 10. Process Quality Management http://www.plant-maintenance.com/articles/RCMvTPM.shtml (11 of 22) [5/15/2004 9:54:53 AM] Examining the Processes of RCM and TPM

An important outcome of this new approach to equipment management which is now supported by many success stories throughout the world in a variety of operational industries, has been that senior management have realised that TPM is both strategically important for a world competitive business, and that TPM cannot be implemented by the maintenance department alone. TPM is a company wide improvement initiative involving all employees.

Although each enterprise may approach TPM in its own unique way, most approaches recognise the importance of measuring and improving overall equipment effectiveness along with the need to reduce both operational and maintenance costs in an environment that promotes continuous improvement.

Understanding the Importance of Overall Equipment Effectiveness Many companies who recognise the important roll equipment and process performance have on bottom-line results are turning to the measure which drives TPM called Overall Equipment Effectiveness (OEE) which incorporates not only Availability but also Performance Rate and Quality Rate. In other words, OEE addresses all losses caused by the equipment: not being available when needed due to breakdowns or set-up and adjustment losses; not running at the optimum rate due to reduced speed or idling and minor stoppage losses; and not producing first pass A1 quality output due to defects and rework or start-up losses. A key objective of TPM is to cost effectively maximise Overall Equipment Effectiveness through the elimination or minimisation of all losses. A simple model outlining these losses is shown in Figure 5.

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When many organisations first measure Overall Equipment Effectiveness it is not uncommon to find they are only achieving around 40% - 60% (batch) or 50% - 75% (continuous process) whereas the international best practice figure is recognised to be +85% (batch) and +95% (continuous process) for Overall Equipment Effectiveness. In effect, this means there exists in most companies the opportunity to increase capacity / productivity by 25% - 100%.

Understanding the Cost Impact of Failure TPM significantly reduces operational and maintenance costs by focusing on the Root Cause of Failure through the creation of a sense of ownership by the plant & equipment operators, maintainers and support staff to encourage "prevention at source". To help understand the thinking behind TPM we need to investigate what causes failure.

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Most of us have heard of the concept of the ‘Root Cause of Failure’ and the tool most commonly used to assist in the search for the root cause – the 5-Whys. The 5-Whys is a simple technique of asking why 5 times recognising that statistically it has been shown that after 5 whys you are most likely to be at the root cause. In the work place we rarely get to the root cause because we are too busy reacting to the symptoms of our problems. However, unless we get to the root cause we will always have problems reappearing.

What is the root cause of failure? Often, before failure we can have poor performance, prior to poor performance we may get moans and groans coming from our equipment, and before the moans and groans we will have accelerated deterioration (see Figure 6).

What do we mean by ‘Accelerated Deterioration’? This is where a piece of equipment or part of a piece of equipment wears out quicker than is expected. That is, its life is shortened because its natural deterioration is accelerated.

Let us look at the failure mechanisms of the parts that make up our plant & equipment. Most pieces of equipment in our plants can be broken up into 3 broad categories:

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From above we can see the different failure mechanisms for the three different categories of items. It is worth noting how TPM will actually reduce the life of your wear items due to the increase in throughput as your OEE increases some 50% or more.

Our main interest however, is with the Working Items. These by far make up the majority of items that need maintenance attention and contribute most to our overall maintenance spend. So let us understand the impact of the laws of physics on our working parts.

If, for example, I were to rub my hands together for the rest of the day what is going to happen? I will get very sore hands as they get several layers of skin rubbed off. To stop this from happening I would need to apply some form of lubrication to act as an interface between my hands.

Hence, proper lubrication provides an interface between moving surfaces, and a key role of lubrication is to be a sacrificial wear element. That is, the lubrication wears out as the moving surfaces interface with it. This is why it is recommended that we replace the oil in our cars at say every 10,000 km. This is not because the oil is dirty, even though it may look dirty it is continuously filtered and clean. The reason for

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Accelerated deterioration occurs when:

❍ lubrication is not present;

❍ lubrication is incorrect for the application;

❍ lubrication between surfaces is forced out due to overload;

❍ lubrication wears out; or

❍ lubrication becomes contaminated.

Who has ever seen an operator “blow down” his equipment with compressed air, or hose it down with water? What is this process doing to the equipment? More than likely the operator is forcing contamination into the equipment without even realising it or caring about it. This contamination is a primary source of accelerated deterioration.

Many studies have been conducted to determine the impact of accelerated deterioration. Let us consider the situation of the working parts of your equipment. If you were to plot say the 30-year history of the actual life of a part that normally fails after 12-months would you get a straight line? In most studies the result is a normal distribution where the part fails for the majority of the time at 12-months however on other occasions it may fail early or later often with a range of some 6-months either side of the 12-month majority. If we were to introduce a periodic or preventive maintenance plan for this part what would be our strategy. Obviously if we were to replace the part after 12-months we would still have a significant number of failures. If we were very conservative we could replace the part every 6-months. This would significantly reduce the failures however we would have very high maintenance cost. So what is the answer?

This is where TPM becomes so important. TPM is based on the precepts of:

❍ understand what causes the variation;

❍ reduce or minimise the variation; then

❍ look to improvement.

Under this approach the first task is to identify what is causing the variation. Studies conducted by the Japanese Institute of Plant Maintenance and companies like DuPont and Tennessee Eastman Chemical Company have shown that 3 major physical conditions make up some 80% of the variation.

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These physical conditions are:

❍ Looseness

❍ Contamination

❍ Lubrication

The elimination of these three conditions is known as “establishing Basic Equipment Conditions”. Once “basic equipment conditions” have been established we find our normal distribution curve squash up some 80% and moves to the right thus significantly increasing the life of our parts.

In his book, TPM in Process Industries, Suzuki raises the important issue when he states:

“Implementing a periodic / preventive maintenance system before establishing basic conditions - when equipment is still dirty, nuts and bolts are loose or missing, and lubrication devices are not working properly - frequently leads to failures before the next major service is due.

To prevent these would require making the service interval unreasonably short, and the whole point of the preventive maintenance program would be lost.

Rushing into predictive maintenance is equally risky. Many companies purchase diagnostic equipment and software that monitors conditions, while neglecting basic maintenance activities.

It is impossible, however, to predict optimal service intervals in an environment where accelerated deterioration and operating errors are unchecked.”

Impact of Multi-Skilling on Basic Equipment Conditions Although multi-skilling has often been successful in creating a more flexible workforce, experience now highlights that while employees move from equipment to equipment, or area to area, they loose the motivation to seek out basic equipment problems or defects which if left unchecked, will cause failure in the future (see Figure 6). The operators often demonstrate a lack of care for the equipment because they know they will soon be moved to another area or piece of equipment.

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An area-based team approach which promotes the development of both base-skills and mastery-skills provides a means to achieve both flexibility and ownership within the workplace. Correctly formed area-based teams create an environment where employees can come to recognise the benefits for themselves to learn both the proper way to operate their equipment as well as how best to care for their equipment by maintaining “basic equipment conditions”.

TPM implementation experience has shown that there is a definite relationship between failures and “basic equipment conditions” – no looseness, no contamination, and correct lubrication. Our experience with multi-skilling is that it takes away ownership and the motivation for operators to ensure basic equipment conditions. Without the framework of effective area-based teams where team members can focus on multi-skilled base skills to ensure team flexibility as well as developing their mastery skills to become the expert at caring for, operating and detecting any defects that might develop in their equipment, operational and maintenance costs will always be high.

Equipment Defects - The Hidden Cause of Failure The key driving objective of TPM is to eliminate or minimise, not just reduce the six big losses. To achieve this, TPM is an ongoing journey to excellence that challenges our mind-sets. One such important challenge is the traditional mind-set that focuses on either actual or potential failures or breakdown and largely ignores equipment defects that can be the hidden cause of failure (see Figure 7).

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Equipment defects or imperfections with our equipment are subtle and not always obvious. They "flow" into our plant & equipment due to various reasons: poor initial design or changes to the initial design requirements of our plant & equipment due to output requirement changes; the way we operate our plant & equipment and the environment we operate our plant & equipment in; imperfections in the maintenance materials we use and the way we carry out our maintenance activities; and last but not least, as a consequence of any failures which occur to our plant & equipment. They are often difficult to identify and correct because they are traditionally accepted as the norm. Equipment defects play a major part in causing "losses" in equipment performance.

TPM implementation experience has shown that there is a definite relationship between failures and equipment defects in that most failures can be traced back to equipment defects. In a TPM environment, the aim is to focus on equipment defects so as to eliminate the occurrence of failures and early deterioration. This focus on equipment defects has a large bearing on the way everyone in the company needs to become involved with TPM. All employees need to ask the question: "are my actions focused on avoiding defects or merely addressing the issues associated with defect removal". Being able to identify and correct equipment defects and then find their source so they can be avoided in the future is a major ingredient in the process of

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Using Operator Equipment Management Pillar to Induce Change Operator Equipment Management is about "caring for equipment at the source" so as to ensure the "basic equipment conditions" are established and maintained to allow the successful implementation of planned preventive and predictive maintenance to be successfully administered by the maintenance department. Ultimately operators become responsible for the overall equipment effectiveness of their plant & equipment through a "root cause" approach to defect avoidance.

It is not a simple exercise to create an area-based team environment that promotes ownership with base skill flexibility and mastery skill specialty. Changes take time. A systematic approach, supported by a robust process, needs to be adopted to allow the changes to be implemented at a rate commensurate with the organisation's evolving culture.

Although implementation of Operator Equipment Management needs to be specific to the situation and plant environment, the final goal of achieving mature equipment- competent area-based teams is for the area-based teams to be responsible for the Overall Equipment Effectiveness (OEE) of their plant & equipment. This does not mean operators carry out all maintenance activities, but that they are responsible for knowing when they need to carry out the simple defect avoidance and maintenance service work themselves and when they should call in maintenance experts to repair problems which they have clearly identified.

The Relationship between RCM and TPM The original precepts for RCM (refer page 3) were developed for the aircraft industry where ‘basic equipment conditions’ (no looseness, contamination or lubrication problems) are mandatory, and where operators (pilots) skill level, behaviour and training is of a high standard. Unfortunately in most manufacturing and mining operations these ‘basic equipment conditions’ and operator skill and behaviour levels do not exist thus undermining the basis of any RCM application.

For this reason, the application of TPM as a company wide improvement strategy is highly advisable to ensure:

❍ ‘basic equipment conditions’ are established; and

http://www.plant-maintenance.com/articles/RCMvTPM.shtml (20 of 22) [5/15/2004 9:54:53 AM] Examining the Processes of RCM and TPM

❍ ‘equipment-competent’ operators are developed

Before attempting a full blown RCM analysis or a partial RCM approach following the basic RCM process. Failure to do this in an environment where basic equipment conditions and operator error are causing significant variation in the life of your equipment parts will block your ability to cost effectively optimise your maintenance tactics and spares holding strategies.

The other key difference between RCM and TPM is that RCM is promoted as a maintenance improvement strategy whereas TPM recognises that the maintenance function alone cannot improve reliability. Factors such as operator ‘lack of care’ and poor operational practices, poor ‘basic equipment conditions’, and adverse equipment loading due to changes in processing requirements (introduction of different products, raw materials, process variables etc) all impact on equipment reliability. Unless all employees become actively involved in recognising the need to eliminate or reduce all “losses” and to focus on ‘defect avoidance’ or ‘early defect identification and elimination’ failures will never be cost effectively eliminated in a manufacturing or mining environment.

Conclusion It should be acknowledged that a TPM implementation is not a short-term fix. It is a continuous journey based on changing the work-area then the equipment so as to achieve a clean, neat, safe workplace through a “PULL” as opposed to a “PUSH” culture change process. Significant improvement should be evident within six months, however full implementation can take many years to allow for the full benefits of the new culture created by TPM to be sustaining. This time frame obviously depends upon where a company is in relation to its quality and maintenance activities and the resources being allocated to introduce this new mind-set of equipment management. The Centre for TPM (Australasia) In January of 1996, the Centre for TPM (Australasia) - a membership based organisation was created with the mission to "promote and advance the knowledge and practice of TPM and conduct, promote and advance the public education of TPM throughout Australasia." The Centre which has it's head office in Wollongong with regional offices in Melbourne, Brisbane and Adelaide, provides networking, information exchange, training and consulting support and has a strong Research, Development & Innovation Division in co-operation with the Business School at the University of Wollongong.

For further information please contact the Centre for TPM (Australasia) on (02) 4226 http://www.plant-maintenance.com/articles/RCMvTPM.shtml (21 of 22) [5/15/2004 9:54:53 AM] Examining the Processes of RCM and TPM 6184.

About the author: Ross Kennedy - President, The Centre for TPM (Australasia) A fitter and turner by trade, Ross has a Mechanical Engineering degree from the University of New South Wales and a Management degree from the University of Wollongong. He has more than 25 years of manufacturing and operational experience covering maintenance, production, operations and executive roles followed by 5 years of international consulting experience with the Manufacturing and Operations Group of Coopers & Lybrand's International Management Consulting Practice. In August 1994 Ross established his own consulting practice specialising in TPM. In January 1996, along with several colleagues, he founded the Centre for TPM (Australasia). Ross has been actively involved with TPM since 1990 and has delivered publicly over 100 papers and workshops on the subject both within Australia and overseas. He, along with his colleagues from the CTPM, is presently assisting a number of companies both in Australia and New Zealand to embark on TPM.

http://www.plant-maintenance.com/articles/RCMvTPM.shtml (22 of 22) [5/15/2004 9:54:53 AM] From Trouble-maker to Trainer Plant Maintenance Resource Center

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Home Articles Webstore Jobs Software Tools Links Search About From Trouble-maker to Trainer Sometimes "problem" employees can be your biggest asset

I was doing a TPM workshop/training class with a large chemical plant in the East. The workshop was scheduled for four days. The first half of the day is spent in the classroom and the second half of the day on the shop floor implementing what we learned in the classroom. We were training a group of 5 cross-functional teams using 5 different pieces of equipment and I went to the plant early on Monday morning to get the classroom set-up and make sure that we had the necessary supplies.

When I arrived at the classroom, there was an older employee waiting in the classroom. I will call him Charlie. When I saw Charlie, I said to him,"You must be real excited about the training since you are here so early"

His reply to me was " NOPE!!," He backed up crossed his arms on his chest and said " I am here because I wanted to talk to you before the class gets started, My supervisor is the dumbest *#%#$^* on the face of the earth. He sent me here to go to this class and waste my time. He thinks that I will learn something new that will help me do my job better. I want to tell you right now that I have been doing this job for 23 years and there is nobody that knows more about my machine and my job than I do. There is

http://www.plant-maintenance.com/articles/charlie.shtml (1 of 4) [5/15/2004 9:55:10 AM] From Trouble-maker to Trainer nothing that you can do to make me change the way I do what I do. I don't need this training and I don't want to be here. I am going to sit over there in the corner and mind my own business. I will leave you alone if you leave me alone!!!"

I immediately shook hands with Charlie and thanked him for telling me how he felt. I asked Charlie if he would mind at least sitting with one of the teams so he wouldn't stand out in the crowd. He agreed and sat at a table with one of the teams when the class got started.

During the first day, Charlie didn't have much to say, but he did not disturb any on the other participants. All during the day he listened and observed. He began to see things that made sense by the end of the first day. During the second day, he actually began to participate with the team he was sitting with. During the third day Charlie really got involved and started working with the team to implement some of the improvements he had heard during the week. By the end of the week Charlie was really getting into it.

He saw that by cleaning the equipment as a form of inspection, tagging and beginning to correct the problems, while brainstorming improvements-and creating standards for the equipment we would make the condition of the equipment much better and that he wouldn't have to struggle to keep the equipment operating. If he kept the process going it would definitely increase reliability and reduce the number of failures, which would make his job easier.

At the end of the week, I had all of the teams develop and make presentations to management-regarding their key learnings and outcomes for the week. The management was so pleased with the outcomes that they decided to train every employee at the plant in the TPM process. I suggested that they allow me to train trainers for the plant and they could provide the workshop for all of the other employees. The plant manager asked me who I thought would make a good trainer for the site, and I suggested Charlie. The plant manager immediately went ballistic saying, "NOT CHARLIE, HE IS A TROUBLE MAKER! He has been a loud mouth and a trouble maker for years." I suggested that Charlie was really involved with the teams during the latter part of the week and that I felt he would be a good trainer. After a great deal of discusson the plant manager

http://www.plant-maintenance.com/articles/charlie.shtml (2 of 4) [5/15/2004 9:55:10 AM] From Trouble-maker to Trainer gave in and said "I guess if you think Charlie can do the job I will let him try."

To make a long story short, Charlie is now a Corporate trainer and travels all over the world providing training for the company. He is an excellent trainer and has become one of the corporations most prized employees.

The moral of the story is that many times the employees who are tagged as trouble makers are the employees that really care about the company. If they didn't care they would keep their mouths shut and not express their feelings. Once an employee like Charlie sees the benefit of a program like TPM they are very difficult to hold back. He became on of the strongest proponents of the whole process, and because he was an informal leader almost everyone would listen to what he had to say. He was very helpful in making TPM a success for the plant and the corporation.

The last time I saw Charlie, he was in an airport headed for Europe. He told me that he was happier than he had ever been in his life and that after nearly 30 years with the company, he finally felt that he was able to make a difference in the success of the company. He somewhat missed the production line, but was glad that he was able to help others like himself. He was now in a position where he could help others see how by using good common sense and applying simple techniques they all could make a difference. He also told me he was sorry he gave me such a hard time the first time we met.--

I have encountered several Charlies during the years that I have been doing TPM training. Almost without exception, once they are given a chance to get involved in improvements and someone listens to their ideas, they become much happier and will work much harder for the success of the company. It emphasizes to me to give the employees that run the equipment a chance to get involved in a hands-on process like TPM and they will make everyone's job easier. If they are known as a trouble maker, they may be one of your best employees hidden in the factory like diamonds in the rough.

http://www.plant-maintenance.com/articles/charlie.shtml (3 of 4) [5/15/2004 9:55:10 AM] From Trouble-maker to Trainer by Michael F. Thomas- Manufacturing Solutions International 7704 Royal Harbour Ooltewah, Tennessee 423-238-7601 Fax-423-238-7602 E-mail- [email protected]

http://www.plant-maintenance.com/articles/charlie.shtml (4 of 4) [5/15/2004 9:55:10 AM] TPM is Priority Number One - TPM es la Primera Prioridad How to Make Cómo Hacer al TPM Everyone's TPM la Prioridad Priority de Todos I am from a automotive parts supplier Trabajo en una planta en el medio oeste in mid-western United States. de los EEUU que suministra partes automotrices. Implementing TPM in a company is not easy. The philosophies of TPM La implementación del TPM en una are not that difficult to understand but compañía no es fácil. No es que las are a some what difficult task to filosofías sean difíciles de entender, sino implement. de llevar a la práctica

In our facility we started with a En nuestra planta comenzamos por una proposal to upper management on propuesta a la alta gerencia sobre las the philosophies of TPM. This started filosofías del TPM. Esto fué un muy buen out to be a really good pep-rally for ensayo general para el TPM en nuestras TPM in our facility, all present saw the instalaciones, todos los ahí presentes benefits of TPM. Everyone was ready vieron los beneficios del TPM. Todos to go, just tell us what we need to do estaban listos para comenzar, "Sólo dí lo and we will be there management que quieres que hagamos y ahí said. Well it really ended up being a estaremos", dijo la alta gerencia. Bueno, let down for us, and what seemed to pues el resultado final fué que nos dejaron be a defeat for TPM. The priorities of sin apoyo a la hora buena, lo que parecía individual management members ser una derrota para el TPM. Las seemed to out weigh the activities of responsabilidades individuales de cada TPM. gerente parecían tener más peso que las actividades de TPM. Later we found this was not entirely true. In all actuality it was partially Más tarde, hallamos que esto no era due to the fault of our own TPM completamente cierto. En realidad la culpa group. We in the group did a "why - era en parte del grupo de TPM. Dentro del why" analysis regarding the lack of grupo hicimos un Why-Why análisis TPM involvement by the organization. respecto del deficiente involucramiento de la organización. Through some very difficult searching for the true root cause, we Aún cuando la causa raíz estaba difícil de came up with this cause: hallar, llegamos a esto:

The organization was waiting for us La organización estaba "esperando" que to show them a direction TPM should nosotros les dijéramos en qué dirección go in. If you remember earlier I said iría el TPM.- ¿Recuerdan que la gerencia management's comments were, "just había dicho: tell us what we need to do." http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/neg2positivetpm.htm (1 of 3) [5/15/2004 9:55:42 AM] TPM is Priority Number One - TPM es la Primera Prioridad

"Sólo dígannos qué necesitamos hacer"? They were waiting on us to give them some guidance on how next to Estaban esperando una guía de nuestra proceed. parte para proceder.

Remember I also said that their Recuerden también que dije que las individual priorities out weighed prioridades de cada gerente parecían those of TPM's. This is very un-true; tener más peso que las del TPM. Esa TPM is used to find areas of concern consideración era totalmente falsa: el TPM and eliminate loss. Most managers se usa para encontrar y resolver areas de are responsible for cost control and preocupación y eliminar pérdidas. La loss control in their own area. mayor parte de los gerentes son responsables por el control de costos y In a nut shell what we did was re-train pérdidas en sus respectivas áreas. ourselves on TPM, and what we saw was we needed to use those priorities En pocas palabras, lo que hicimos fué of the managers and department reentrenarnos en TPM, y lo que teníamos heads as milestones for TPM que hacer era aprovechar esas prioridades activities, and even success de los gerentes como puntos de referencia measurables if you will. para las actividades, y hasta mediciones de efectividad si se quiere, del TPM.

This allowed us to bring TPM closer Esto nos permitió acercarnos a nuestro to home as far as the departments objetivo en lo que a los departamentos se were concerned. We are in the refería. Ahora estamos en el proceso de process now of forming a "TPM armar una "Guía de Implementación de Implementation Guide" plantwide. Its TPM" dirigida a toda la planta. Su parte main body will show how the tools of principal será dedicada a mostrar cómo TPM will be a spear head for helping las herramientas de TPM serán la punta de the departments achieve their goals & lanza para ayudar a cada departamento a objectives. Doing this tunes everyone alcanzar sus objetivos y metas. Hacer Into the same frequency of the esto, "sintoniza" a todos en la misma program. frecuencia del programa.

This is what I would recommend for Esto es lo que yo recomiendo para la implementing an organizational implementación de filosofías de philosophy change such as TPM or organización tales como TPM, o Lean Manufacturing etc. Have a few Manufactura Esbelta, etc. Haga que members of your organization receive algunos de los miembros de su as much training and knowledge on organización reciban tanta capacitación y the ideas and activities as possible. entrenamiento como sea posible en las Then have them trained in the art of ideas y actividades a implementar. Luego re-education. Change is difficult no hágalos entrenar en el arte de la re- matter what implement of change educación. El cambio es siempre difícil, your organization chooses to follow. cualquiera que sea el cambio que la organización haya decidido hacer. Fear of change is the biggest hurdle to overcome for everyone. The only El miedo al cambio es la parte más difícil way to do this is through education. http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/neg2positivetpm.htm (2 of 3) [5/15/2004 9:55:42 AM] TPM is Priority Number One - TPM es la Primera Prioridad

The educated will succeed the de superar para cada quien. La única illiterate will fall behind. forma es mediante educación. Los educados tendrán éxito, los ignorantes "The illiterate of the sucumbirán. future are not those who can't read or write "Los analfabetas del futuro no son los que but those who cannot no saben leer o escribir, sino los que no learn, unlearn, and re- puedan: learn. aprender, des-aprender y re-aprender."

'Alvin Tofler - - Alvin Toffler -

Buena suerte en su jornada hacia el Good luck on your quest for change. cambio. No importa si usted manufactura It doesn't matter if you manufacture juguetes o barcos, la educación es la toys or ships, education is the key. clave.

John Auskamp

TPM Group American Showa Blanchester Plant John Auskamp

TPM Group American Showa Blanchester Plant

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Feature Article Click the books for Looking for more? The Magical Matrix: our Suggested Click here to visit Simple Graphic Can Be Reading List Inspiring our extensive archive of unique articles.

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The Magical Matrix Simple Graphic Inspires Creative Thinking, Problem Solving

By Susan Ferguson, Strategic Work Systems’ basic skills specialist

Last month, I wrote about how to use graphical data from the workplace to improve thinking skills among your employees. This month, I’m writing about the matrix. Not the movie, not hair care products, but the deceptively simple graphic made up of Site Highlights intersecting columns and rows. Its design might be simple and unsophisticated, but

Products: its power is undeniable. TPM supplies that deliver Long before I ever used the word matrix, I used self-made charts to keep up with results fast! Don´t miss our things. When I taught school, I used one chart to mark students’ attendance and books: Visual another to determine whether they had turned in all of the papers and projects that Systems & were due. As a retailer, I used a chart to track sales figures, monitor sales by item Proven Tips and post schedules for part-time sales staff. I used a large hand-drawn calendar to Library: A new keep up with scheduled activities and deadlines. For years, I used various versions of article each my “charts” without giving any thought to why I chose to use them or why they month, a link to our worked so well for me. archives, plus suggested reading I don’t know when I started using the term “matrix” or began to use a matrix to guide my thinking or to aid me in problem solving, but I do know when I started Services: How thinking about how and why it works. That was the first time I taught a class how to can we help you strive for read and use common job-related forms. world class? Who We Are: I collected forms from the company where the class was scheduled and sorted them Meet our pit by type: graph, flowchart, schematic, and matrix. The matrix pile was the tallest. crew and read our Among the forms were check sheets, run charts, English-metric conversion charts, Credo. replacement parts order sheets, and the shift rotation schedule. These forms, though all matrices, were varied, often complicated to read, and filled with information that http://www.swspitcrew.com/html/library.htm (1 of 3) [5/15/2004 9:56:18 AM] Strategic Work Systems - Library

Links: Visit was critical to the company’s processes. It was clear to me that a lesson, or two, on some of our the matrix would be necessary for the class on forms. favorite sites. Home: An overview of In the process of preparing the lessons, I looked up the definition of matrix. I always Strategic Work Systems, Inc. look up, in advance, the words I am going to ask the students to look up. My lesson plan, and maybe life, was changed by what I read. The first definition read: “a situation or surrounding substance within which something else originates, develops, Seminars or is contained.” The second read: “The womb.” The third: “That which gives form or origin to anything.” Not until definition four did I find the mathematical Overview definition: “a rectangular array of elements set out by rows and columns.” Were the mathematicians thinking logically when they named that chart “matrix,” which is

TPM from the Latin word for mother?

If the intersection of column and row produces a cell that holds information that is Precision Maintenance exclusive to that column and row, maybe that cell is the mother of an original idea, a different answer, or a new way of looking at a problem. If that is the case, a matrix is more than an organizing tool for gathering information and making decisions. It can How to also be used as a tool to encourage creative thinking and problem solving. Reach Us Call (864) 234-3100 You can test this hypothesis by giving this exercise a try: Fax (864) 234-3101 The Safety Matrix

Click the light bulb to send us Fill in each cell of the matrix with a safety-related word or phrase that begins with suggestions, the letter at the top of the column and applies to the place in the left-hand column. comments, or questions. S A F E T Y

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Did you feel yourself thinking outside-of-the-box to fill in the boxes? I couldn’t fill all of the cells on my first try. Hours later, an answer would pop into my mind. After a day or two, even after all my boxes were filled in, more possibilities came to me. My brain was working overtime, on autopilot, to find answers to the problem I had given it.

I get the same results every time I use this exercise in class. We usually do the On

http://www.swspitcrew.com/html/library.htm (2 of 3) [5/15/2004 9:56:18 AM] Strategic Work Systems - Library Your Job row as a class activity and then I ask students to take it home to work on. They come to class the next day with great stories about how answers came to them when they were on the job or driving or working in the garden or taking a shower. Good answers. Creative answers. Answers that stretch the rules. New and original answers. Clearly, their minds have been working overtime, on autopilot, too. In one company, this same exercise was used to come up with slogans for a new safety campaign. In another, the technique was used to brainstorm ways to reduce waste of caustic, which is a very expensive material used in their manufacturing process.

The lessons I teach about the matrix include the basic concepts of locating needed information on charts made up of columns and rows and entering information into the correct boxes on blank forms. But the real learning that happens during those lessons comes when we do exercises where the students come up with original information to fill the cells of a pre-built matrix or when they build the matrices from scratch. The cells of the matrix serve to inspire creative thinking. In class, as in the workplace, you always get better results when the minds of the players are in thinking mode.

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http://www.swspitcrew.com/html/library.htm (3 of 3) [5/15/2004 9:56:18 AM] http://membres.lycos.fr/hconline/5S/deployment.html 5S deployment best in 1024x800 HOME Maintenance Portal 5S Portal French version AUTHOR Last update: December 1st, 2003 Deploying 5S Quick hits 5S quick hits is a condensed yet violent method chosen by Implementing 5S can be done in two ways: management or purposely recommended by consultants. ● "Quick hits"; a high density approach deploying the whole 5S principles in a very short period of time, generally 3 to 5 days. It's a kind of tidal wave starting with a cleaning-sorting-disposing initial phase. It shakes the slumbering teams

● The "5S workshop", over a longer period of time and addresses the several principles in a gradual way. and instals the new rules in a very short time. The impulse given must quickly be Both ways have advantages and inconvenient. The choice depends on management targets and company's culture. followed by others in other areas of In any case, regardless to the way it is conducted, the 5S implementation must be managed like a project. the workshop or plant.

Managing a project means define objective, gates and milestones and the scheduling. A project leader is to take responsibility and a workgroup called together. Key to success are steady efforts, rythm, total involvement of The workgroup, via the project or team leader has to report regularly the progress. Top management must be management and quality of demanding for information and the timekeeping. tutoring to insure a sustained effort. If the 5S project is to be recognizes as important for the company, it must be driven like any other company project, with same management involvement and availability of resources.

Main milestones of 5S project Management involvement This scheme is just an example. Each project leader, each company has to adapt the planning to its objectives and context. Manager's involvement, so often required and sometimes criticized, Preliminaries must be real.

Before kick-off, communicate about project's targets and objectives, setup the project structure and It ensures means and resources choose carrefully the pilot site where to start. necessary to carry out the project, Make sure the necessary resources and means are available for the start. as well as interest for results and communication about project and achievements. Training The actors (those carrying out the Starting 5S is a good opportunity to perform on-the-job training with tutoring. action) on the shopfloor are often too demanding toward management, awaiting too much This way holds several advantages: from management's involvement. It is not up to directors and chiefs

❍ Give a meaning to the project so it makes sense. to carry out 5S actions ! Trainer has to explain goals and expectations, Why to choose this method and how it works. http://membres.lycos.fr/hconline/5S/deployment.html (1 of 3) [5/15/2004 10:12:51 AM] http://membres.lycos.fr/hconline/5S/deployment.html

5S are meant to improve working ❍ Favor buy-in. people, employees work One involves even better in a project if he understands the reasons, targets and when the environement, setup their own advantages and benefits have been demonstrated. new housekeeping (and working?) rules and foster their autonomy on

❍ Get funds from training fund (in France). those topics.

Kick-off The counterpart to this freedom to build the new environment, is the As a first action, a thorough white tornado should sort out and dispose all unnecessary, obsolete, out shopfloor people's activ of order and worn out items stored on shelves, workbenches, desks and in closets. Clean and arrange participation and their properly remaining items once. involvement.

Define rules

The next step is to define a set of (new) rules sustaining these first progress. These rules must assign storage place for tools, parts and documents according to their frequency of usage. By the way, the first results should be improved; like getting rid of items whose usage frequency and value was unclear (use statistical methods, like tally tags), improve cleaning techniques to ease it.

Focus on letting the dirt and mess show, so people will eliminate it. Every failure in 5S discipline must be visible, but furthermore be disturbing for the new harmony.

Set standards

The new "housekeeping" or industrial hygiene rules must be a subset of other work rules and procedures.

Define means and ways to check the respect to these 5S rules, as well as the frequency of the checking. Generally internal audits or self-assesments are performed by patrols. Patrols members should be a mix of workers, foremen, managers, office emplouees. These audits or assesment require standard forms and a guidebook. Results must be displayed quickly and publicly. they must be reported in a clear and simple manner by the biggest number, so to advertise about the efforts and the achievements.

Progress

Last but surely not least is to make the system and results improve.

Cleaning, sorting, ordering, make easier, better, faster...the first results can be improved. The rules and standard may need to be updated to take inot account the new achievements, raising the standards, hense the objectives.

http://membres.lycos.fr/hconline/5S/deployment.html (3 of 3) [5/15/2004 10:12:51 AM] Is your Implementation Going Slower Than Expected?

Is Your Implementation Process Going Slower Than Expected?

Enrique Mora

One of the main problems when establishing these disciplines, either TPM or any other Lean Manufacturing strategy, is that when all is said and done, the effort is diluted and eventually gets lost. This is a worse consequence than if the effort had never started.

We have found this a common source of frustration in a big number of companies. What happens is that there is a mistaken idea that it is sufficient to have a handful of people trained in these disciplines, usually supervisors or managers. Unfortunately, they are still of the old management style where they consider their function is that of a boss.

http://tpmonline.com/articles_on_total_productive_maintenance/management/slowerthanexpected.htm (1 of 5) [5/15/2004 10:13:05 AM] Is your Implementation Going Slower Than Expected?

The reality is some of these people feel that with the implementation they will lose power. The truth is that yes, they will lose the power of giving orders, but for those who become true leaders, they acquire the new power that comes from the respect and admiration of their team members.

The process is simple, perhaps, that is the reason why key points can be overlooked although they are crucial to the success of the implementation.

The steps are relatively easy to follow:

1) Only issue invitations and accept those people who show interest and enthusiasm about learning advanced productivity technologies. Never include people in the projects by force or command.

2) Make an appropriate mixture of operators, leaders (supervisors and managers), engineers, staff personnel, etc.

3) Develop an atmosphere of authentic leadership by making them aware that their ideas and voices will be heard; where people cooperate by their own will http://tpmonline.com/articles_on_total_productive_maintenance/management/slowerthanexpected.htm (2 of 5) [5/15/2004 10:13:05 AM] Is your Implementation Going Slower Than Expected? of being part of the success.

4) Cross-training is a key element in understanding how everyone's job fits into the big picture. This promotes an atmosphere of Cooperation and Motivation.

5) Constantly acknowledge and recognize people's ideas and contributions.

6) Listen to all with attention and try to put into practice their creativity and ingenuity in minor or big improvements to the processes, work areas, machines, facilities, and the product.

7) Close each event making sure that each person learned something, and felt great satisfaction for the achievements. Have the participants express these achievements in the presentation to management.

8) Emphasize that management recognizes these achievements and commits to keep supporting the continuous improvement process.

If any one of these points is not thoroughly completed, it can mean that the effort will have poor results or fail.

http://tpmonline.com/articles_on_total_productive_maintenance/management/slowerthanexpected.htm (3 of 5) [5/15/2004 10:13:05 AM] Is your Implementation Going Slower Than Expected? Therefore, it will be a waste of your invested time and resources.

We are prepared to help you recapture control and to make the Kaizen power yours.

Click here to send us an email, we will give you our comments without any strings attached.

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http://tpmonline.com/articles_on_total_productive_maintenance/management/slowerthanexpected.htm (5 of 5) [5/15/2004 10:13:05 AM] Kaizen Events Continuous Improvement - Mejoramiento Continuo con Kaizen

Kaizen = Continuous Improvement

Enrique Mora (a) Papá Kaizen

One of the key elements for the implementation of the good philosophies of Lean Manufacturing is without a doubt the "Kaizen Event". Kaizen is, as many of you know, a Japanese word meaning "Continuous Improvement". We at MORA, LLC have developed this kind of environment in many plants and the most diverse industries with a 100% success rate.

Actually, a Kaizen Event can be set in a few hours or a few days, but the results are so fulfilling, that the people directly involved in it will keep doing their best in order to increase the good results. It is a matter of conditioning to the rewards.

http://www.tpmonline.com/articles_on_total_productive_maintenance/leanmfg/kaizenevents.htm (1 of 5) [5/15/2004 10:13:15 AM] Kaizen Events Continuous Improvement - Mejoramiento Continuo con Kaizen My friend Bob Rosinski explained to me how a 3 ton. whale can jump 20 feet out of the water with astounding precision. She is conditioned to the rewards of success. The first jump was just a few inches when she was a baby, but the piece of fish the trainer offered as a reward was delicious. Then, she kept finding out that in order to keep getting rewards, she should have to jump higher and higher all the time. Later, there is the fish and the applause, double reward! If the bar she has to jump goes ½" higher each time she will just not notice. Of course there is a limit to everything.

Well, in these times of global competition, all the people who want to stay in business are having to learn the very same lesson. The marketplace is the bar that we have to jump and reach in order to keep getting the rewards. And there is no doubt, the bar is raised constantly by the fierce competition. If we want to play in the big leagues, if we want to keep our share in the market, our performance must be among the highest standards possible.

We create in your site the correct challenge that will make the efficiency grow to fit the demands of your market, so you do not lose your share of participation in it.

Kaizen is the answer. If nothing else, focus on one product, say one of those products you sell the most. Womack & Jones in their book "Lean Thinking" (Click on the title to read more about it), show the case of an Indiana factory which president Joe Day made a very interesting discovery. In his implementation of lean disciplines, no matter how many times his employees http://www.tpmonline.com/articles_on_total_productive_maintenance/leanmfg/kaizenevents.htm (2 of 5) [5/15/2004 10:13:15 AM] Kaizen Events Continuous Improvement - Mejoramiento Continuo con Kaizen improved some operation, they will always find some new way of improving the improved. The search for perfection. In three and a half years they accomplished improvements of about One Thousand per cent, that is ten times as good!!! One of our customers in California saw the sales raise in more than 10,000 times per year compared to the investment in our services. That is, if they only have a profit of 20% in their product, a cumulative return on investment of more than TWO HUNDRED THOUSAND PER CENT EVERY YEAR!!!

Kaizen Events when repeated have three effects equally beneficial: They generate PROFIT, SAVINGS and perhaps the best of all, they GENERATE A HABIT OF SUCCESS. The habits create a culture and that is what lean manufacturing and other best practices are all about.

We will be pleased to have the opportunity to bring these benefits to your plants. Click here to schedule an appointment and for a fee of only $100.00 we will come to your site and show you some opportunities that are already there.

The E-book "The Power of Kaizen Events" by Enrique Mora, is ready for you to start reading in a few minutes... and for just $ 7.99 (only this week). No downloads, Continuously Updated! Just click HERE

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If you want to see a list of books on this exciting subject, click here.

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Maximized Manufactura Maximizada Manufacturing Reaps Cosecha Recompensas en Rewards at Whirlpool- Whirlpool-Findlay por James K. Ryan, Marshall Institute, Inc.; Findlay con colaboración de Kirk Wolfinger, Tom by James K. Ryan, Marshall Institute, Meyer y Jim Dray, de Whirlpool Corp., Inc.; with Kirk Wolfinger, Tom Meyer & Findlay, Ohio Jim Dray, Whirlpool Corp., Findlay, Ohio Traducción de Enrique Mora © ©

Imaginen apoyar una plan de actividades que Imagine supporting a business plan that requiere una transición hacia manufactura requires a transition to pull adelantada, (pull manufacturing), al tiempo manufacturing, while reducing work in que se reduce el trabajo en proceso y el process and finished goods inventory. inventario de producto terminado. La The industry demands continuous industria demanda un flujo constante de supply of product to the customer’s producto al consumidor al precio justo, en la hands at the right price, in the right cantidad correcta y con la más fina calidad. Y quantity, and of the finest quality. And mientras la demanda de producto va en while demand for product is increasing, aumento, no hay presupuesto para capital dollars for expansion are not expansión. Ya sabemos la historia: Si available. If you can’t supply the nosotros no cubrimos la demanda del customer, you know the story, your consumidor, nuestros competidores lo harán. competitors will.

Si consideramos el costo de la oportunidad When you consider the cost of lost perdida también conocido como costo de opportunity, also known as cost of inconfiabilidad (CoUR), las pérdidas unreliability (CoUR), the potential losses potenciales son asombrosas. Aún más are staggering. In addition to lost sales, amenazante que la pérdida de las ventas es la loss of marketshare is even more pérdida de la participación en el mercado. threatening.

En la División de Findland Ohio de la At Whirlpool Corporation’s Findlay, Whirpool Corporation, la demanda de Ohio Division, demand for product is at producto está en su ,más alto nivel de todos an all-time high. The Findlay Division los tiempos. Esta división fabrica lavadoras manufactures dishwashers for de trastos para Kenmore, KitchenAid, Estate, Kenmore, KitchenAid, Estate, Roper, Roper, Inglis y la propia marca Whirpool. El Inglis, and Whirlpool brand. The objetivo de esta instalación industrial era el objective for this manufacturing facility definir ¿Cómo producir más con el equipo was how to get more out of the facility existente y sin grandes inversiones de http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/whirpoolcase.htm (1 of 9) [5/15/2004 10:13:25 AM] Maximized Manufacturing - Manufactura Maximizada

and its equipment without making huge capital? Y más específicamente para Kirk capital investments? And more Wolfinger, gerente de Mantenimiento e specifically, for Kirk Wolfinger, manager Ingeniería de la Planta: ¿Cómo puede el of maintenance and plant engineering, departamento de mantenimiento atender las how can the maintenance department necesidades de manufactura para alcanzar support the needs of manufacturing to los objetivos de la empresa? achieve the company goals? In 1995, Wolfinger patrocinó un equipo de In 1995, Wolfinger sponsored a cross- personal experimentado multidisciplinario functional team of skilled trades para desarrollar el Plan Maestro de personnel to develop a Maintenance Mantenimiento y Suministro de Herramental, and Tooling (M&T) Department Master (M&T por sus siglas en inglés). Este equipo, Plan. This team, along with assistance con apoyo de sus asociados de producción, from their production partners, set forth se abocó a desarrollar un plan para mejorar la to develop a plan that would allow the productividad a base de eliminar tiempos plant to improve production rates by perdidos. Esta visión de "cero tiempo eliminating unplanned downtime. The perdido" fué un significativo cambio cultural vision of zero unplanned downtime, y fué logrado mediante planeación mejorada, which was a significant culture change, mantenimiento preventivo específico para would be supported by improved cada máquina, uso de más tecnologías de planning, machine specific preventive mantenimiento predictivo, TPM, análisis de maintenance, more utilization of raíz de fallas, y el programa de Excelencia predictive maintenance technologies, Operacional de la compañía (Six Sigma). TPM, root cause failure analysis, and the company’s Operational Excellence Este Plan Maestro M&T, junto con las (Six Sigma) program. iniciativas de mejoramiento emprendidas en Whirpool-Findlay evolucionaron en lo que The M&T Master Plan, along with the hoy se conoce como "Manufactura resulting improvement initiatives at Maximizada", un término acuñado y Whirlpool-Findlay evolved into what is fuertemente apoyado por Mark Buehrer, now known as "Maximized director de operaciones de la planta. La Manufacturing," a term coined and Manufactura Maximizada subraya la strongly supported by Mark Buehrer, importancia de alinear muchas diferentes director of plant operations. Maximized iniciativas de mejoramiento en un esfuerzo Manufacturing underscores the conjunto que se enfoca por entero a mejorar importance of aligning many different la eficiencia como resultado, "maximizar" los improvement initiatives into a single procesos de manufactura. effort that focuses totally on improving efficiency and ultimately "maximizing" Para efectuar estas mejoras, la División manufacturing processes. necesitaba obtener una medida de la eficiencia inicial del equipo. La herramienta To make these improvements, the utilizada fué la Eficiencia Total del Equipo Division needed to obtain a measure of (OEE por Overall Equipment Eficiency), http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/whirpoolcase.htm (2 of 9) [5/15/2004 10:13:25 AM] Maximized Manufacturing - Manufactura Maximizada

their current equipment efficiency. The piedra angular de la metodología del tool they used to do this was Overall Mantenimiento Productivo Total (TPM). OEE Equipment Efficiency (OEE) rating, a permite medir las condiciones actuales del cornerstone measurement of the Total equipo y puede detectar ganancias futuras. Productive Maintenance methodology. La fórmula básica de OEE es simple: OEE assesses the current status of Disponibilidad X Desempeño X Calidad. Esta equipment and can track future gains. simple fórmula transforma datos The basic formula of OEE is Availability rudimentarios en una interpretación x Performance x Quality. The formula significativa de qué tan bien se utilizan los turns raw data into a meaningful recursos de equipo. A menor OEE (mostrado interpretation of how well equipment en términos de porcentaje tal como 78%), resources are utilized. The lower the mayores son las oportunidades de mejorar. OEE (usually shown as a percentage, such as 78%), the more opportunity for A medida que la empresa comenzó a detectar improvement. los porcentajes individuales de OEE de las máquinas, se vió claro que había espacio As the company started tracking para mejoramiento. "La baja eficiencia del individual pieces of equipment’s OEE equipo se puede asociar directamente a la ratings, it became apparent that there necesidad de: percepción de la propiedad y was room for improvement. "The low del uso de herramientas para resolver equipment efficiency could be tied problemas por parte de los operadores del directly to a need for more ownership, equipo y el personal de mantenimiento," dijo awareness, and use of problem solving Wolfinger. tools by the equipment operators and maintenance personnel," said Bajo la sombra de la Manufactura Wolfinger. Maximizada, personal de operaciones y mantenimiento unieron sus fuerzas. Y estas Under the Maximized Manufacturing son las palabras del facilitador de TPM, Jim umbrella, operations and maintenance Dray: "fué la gente la que hizo posible este personnel joined forces. And in the cambio". Pero el cambio no resultó fácil. words of Jim Dray, TPM Facilitator, "it was the people that made this change Cuando se inició el proceso de possible". But the change did not come implementación TPM, había muchos easy. escépticos. Muchos veían al TPM como otro "programa del mes". Como con cualquier When they first started initiating the nueva iniciativa de mejoramiento, la gente TPM process, there were many skeptics. estaba recelosa al cambio. Lo que ellos no Many viewed TPM as another "program sabían es que TPM no es un programa, sino of the month". As with any new un cambio cultural respecto al mantenimiento improvement initiative, people were del equipo y la manufactura del producto. sensitive to change. What they didn’t know was that TPM was not a program, Lo que la gente de la División Findlay estaba but a true cultural change in the way experimentando no era muy diferente de lo http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/whirpoolcase.htm (3 of 9) [5/15/2004 10:13:25 AM] Maximized Manufacturing - Manufactura Maximizada

that the equipment is maintained and que lo que la mayoría de la gente siente the product is manufactured. cuando se implementa el TPM. En general, la gente siempre quisiera seguir haciendo las What people at the Findlay Division cosas de la misma forma, se resisten al were experiencing wasn’t anything cambio. Pero para ser competitivos en una different than what most employees feel industria tan intensamente competida, las when implementing TPM. In general, cosas deben cambiar. El mejoramiento people would prefer doing things the contínuo debe convertirse en una forma de same way; they resist change. But to be vida. competitive in an intensely competitive industry, things must change. Como resultado del Plan Maestro M&T, los Continuous improvements must be a empleados de la División Findlay habían way of life. introducido mantenimiento preventivo, mantenimiento predictivo y programas de As a result of the M&T Master Plan, análisis de causa raíz, pero todavía tenían employees at the Findlay Division had demasiado mantenimiento reactivo. También introduced preventive maintenance, necesitaban una herramienta para poner en la predictive maintenance, and root cause misma línea a mantenimiento y operaciones. analysis programs, but they still had too much reactive maintenance. They also Para asegurar la efectividad de la needed a tool to align maintenance and Manufactura Maximizada, y más operations. específicamente para combinar los diversos esfuerzos enfocándolos hacia mejorar la OEE. Whirpool había trabajado previamente To insure the effectiveness of con Marshall Institute de Raleigh NC, Maximized Manufacturing, and more consultores en manufactura y mantenimiento, specifically, to combine the various en las etapas iniciales del Plan Maestro M&T. efforts to focus on improving OEE, Lo que estaban buscando era una Whirlpool sought out the services of herramienta que habilitara a toda la Marshall Institute, a Raleigh, NC based organización para visualizar y sentir lo que se manufacturing/maintenance consulting ve y siente al lograr confiabilidad. Mejorar la firm. Whirlpool had worked with confiabilidad de la planta no era solo en favor Marshall earlier, at the initial stages of de los intereses de Whirpool; era el mejor uso the M&T Master Plan. What they were de los recursos para los empleados que looking for was a tool that would enable laboraban en la planta. Esa herramienta fué: the entire organization to see and feel "El Juego de la Manufactura" (The what reliability looked and felt like. Manufacturing Game ™). Improving the plant’s reliability was not only in the best interest of Whirlpool; it "Habíamos estado usando este juego de was the best use of resources for the simulación por más de un año con uno de employees who worked at the facility. nuestros más grandes clientes y pensamos That tool was The Manufacturing que le vendría bien a las necesidades reales Gametm. de Whirpool", dijo Dale Blann, Ejecutivo http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/whirpoolcase.htm (4 of 9) [5/15/2004 10:13:25 AM] Maximized Manufacturing - Manufactura Maximizada

Principal de Marshall Institute. "Sabíamos "We had been using this simulation for que la fuerza laboral de Findlay tenía gran over a year with one of our large clients habilidad y motivación, el problema era and thought it was a perfect fit with alinearlos a todos en la misma dirección. Lo what the group at Whirlpool really que permitió "El Juego de la Manufactura" fué needed," said Dale Blann, CEO, que grandes grupos de gente experimentaran Marshall Institute. "We knew that the en sólo dos días, la transición entre un workforce at Findlay was highly skilled mundo reactivo a uno extremadamente and highly motivated, but the problem confiable". was getting everybody aligned in the same direction. What The La combinación de prácticas fundamentales Manufacturing Game did was to allow de mantenimiento tales como el análisis de large groups of people to experience in causa raiz de las fallas y los sistemas de two short days, the journey from a mantenimiento preventivo y predictivo, junto reactive world to a extremely reliable, con un apoyo muy fuerte del liderazgo de la proactive one." División, permitieron que el grupo de Findlay "levantara vapor" en su implementación de The combination of fundamental TPM. El Juego de la Manufactura ha ayudado maintenance practices such as root a demostrar cómo múltiples inoiciativas cause failure analysis and a pueden trabajar juntas hacia el logro de una preventive/predictive maintenance meta común de mejoramiento de la eficiencia system, along with very strong support de la planta. from Division leadership, enabled the Findlay Division to gain steam in "Los primeros esfuerzos TPM no siempre nos implementing their TPM system. The permitieron reunir a la gente adecuada en las Manufacturing Game has helped juntas del equipo de trabajo. Sabíamos que la demonstrate how multiple initiatives gente que opera y mantiene las máquinas son can work together toward los verdaderos expertos para mejorar el accomplishing a common goal of desempeño. El formato de "El Juego de la improved plant efficiency. Manufactura" nos ha permitido combinar grupos de operadores de producción, gente "Initial TPM efforts didn’t always allow experta en oficios, y personal gerencial en us to get the right people together for una meta común que nos va a brindar un team meetings. We know that the mejoramiento específico en su área de people operating and maintaining the trabajo. Nuestra expectativa es que al equipment are the real experts to completar el proyecto inicial, los equipos de improving performance. The format of trabajo continuarán considerando nuevos the Manufacturing Game has allowed us proyectos de mejoramiento", dijo Dray. to combine teams of production operators, skilled trades, and El Juego de la Manufactura brinda una management to work on a common goal excelente oportunidad para que gente que a that will provide a specific improvement veces tiene enemistades, se combinen en un in their area. Our expectation is that equipo de trabajo, dirigiéndose a la meta http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/whirpoolcase.htm (5 of 9) [5/15/2004 10:13:25 AM] Maximized Manufacturing - Manufactura Maximizada

upon completion of the initial project, común de mejorar la eficiencia de la planta. the teams will continue by considering De acuerdo con Tom Meyer, Ingeniero de other improvement projects," said Dray. Mantenimiento, "alguna de nuestra gente realmente ha cambiado su forma de ver el The Manufacturing Game provides an trabajo como resultado de tener que ponerse excellent opportunity for people that [en los zapatos de los otros] durante la sometimes have adversarial simulación en el juego." relationships to come together as a team, working towards a common goal "Los mejoramientos masivos que hemos of improved plant efficiency. According hecho en nuestros resultados de OEE son un to Tom Meyer, Maintenance Engineer, reflejo directo del esfuerzo de nuestra gente "some of our people have really en el piso," dijo Wolfinger. "Fuimos muy changed the way they go about their afortunados de hallar las herramientas que work as a result of having "walked in permitieron a nuestra fuerza de trabajo ver the other guy’s shoes" during the game cómo corre una planta completamente simulation." confiable. Sin esa herramienta, no creo que lo hubiéramos logrado tan rápido." "The massive improvements we have made in our OEE numbers are a direct "En contraste con algunos de nuestros reflection of the efforts from our people pensamientos anteriores, aprendimos que la on the floor," Wolfinger said. "We were respuesta no es necesariamente el asignar very fortunate that there were tools más gente al mantenimiento preventivo, pero available to us that allowed our realmente reducir el mantenimiento reactivo workforce to see how a completely mediante eliminar los defectos que causan reliable plant ran. Without that tool, I los paros de producción", dijo Meyer. "Esto a don’t know that we would have gotten su vez nos permite aplicar más tiempo en las where we are so quickly.’ tareas correctas, el trabajo proactivo que directamente mejora la disponibilidad de la "In contrast to some of our previous planta." thinking, we learned that the answer is not necessarily to assign more time to Los equipos de acción han aplicado varias PM, but to actually reduce the reactive técnicas de entrenamiento, en conjunto con work by eliminating the defects that los principios de "El Juego de la cause breakdowns," Meyer said. "This Manufactura" para alcanzar mejoras in turn allows us to spend time on the fenomenales en el porcentaje de OEE en right things, the proactive work, which muchas máquinas. Todo esto se combina en directly improves our plant availability." lo que Jim Dray llama el cambio de paradigma del TPM: "Todos somos responsables por Action teams have applied various nuestra maquinaria." El Taller del Juego de la training techniques, along with The Manufactura también crea la espectativa en Manufacturing Gametm, principles, to cada participante de que su máquina puede record phenomenal improvements in desempeñarse mejor, y la vida en el trabajo OEE numbers on many pieces of también puede ser mejor - si todos jalamos http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/whirpoolcase.htm (6 of 9) [5/15/2004 10:13:25 AM] Maximized Manufacturing - Manufactura Maximizada

equipment. This fits together into what parejo y trabajamos en la eliminación de Jim Dray calls the paradigm shift of defactos como un equipo. TPM: "We are all responsible for our equipment". The Manufacturing Game Asi que ¿Cuáles son los resultados de ma Workshop also instills an expectation Manufactura Maximizada en Findlay? La among the participants that their División ha podido aumentar la producción equipment can perform better, and work en un 21% sin costo monetario significativo. life can be better - if we all pull together "Nos sentimos muy cómodos de que estas and work on defect elimination as a son realmente ganancias en producción, no team. números inflados. El aumento en la disponibilidad de producto es un resultado So what are the results of Maximized directo de que nuestra gente tomó el sentido Manufacturing in Findlay? The Division de propiedad de la maquinaria mediante las has been able to increase production by metodologías del TPM," de acuerdo con Kirk 21%, without any significant capital Wolfinger. costs. "We feel very comfortable that these are actual production gains, not En este ambiente altamente competitivo, inflated numbers. The increased Whirpool-Findlay no está durmiéndose en sus product availability is a direct result of laureles. El equipo de trabajo ha desarrollado our people taking ownership in their un sistema de sólida responsabilidad por la equipment through methodologies of empresa que permite a esta División TPM," according to Kirk Wolfinger. mantener las ganancias y el escenario adecuado para nuevas mejoras contínuas. El In this intensely competitive sistema incluye el establecimiento de un environment, Whirlpool-Findlay is not consejo TPM, constituido de gente muy resting on its laurels. The team has experimentada, y son responsables de revisar developed a solid accountability system y de certificar a los nuevos grupos TPM. En that will allow the Division to maintain adición, un comité activador de TPM hecho the gains and set the stage for de gerentes de producción y mantenimiento continued improvements. This system se reúne cada mes para ratificar el progreso includes establishment of a TPM de los grupos TPM. Este grupo también Council, made up of the senior leaders, comparte las mejores prácticas y encuentra responsible for reviewing and certifying nuevas formas de promover el TPM a través all new TPM teams. In addition, a TPM de toda la planta. También se encargan de Steering Committee made up of asignar la gente específica para encabezar la production and maintenance managers, implementación en cada máquina y asegurar meets monthly to review the progress of que se sostenga el esfuerzo después de la all TPM teams. The group also shares implementación. Este sistema de best practices and looks for ways to responsabilidad junto con revisiones promote TPM throughout the plant. The mensuales de la OEE de cada máquina han system also includes assigning specific permitido a Whirpool-Findlay asegurar la people to specific pieces of equipment continuidad de este éxito. to lead TPM implementation and ensure http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/whirpoolcase.htm (7 of 9) [5/15/2004 10:13:25 AM] Maximized Manufacturing - Manufactura Maximizada

that it is sustained after implementation. This accountability system, along with monthly reviews of all the equipment Libro relacionado: OEE ratings, has created a means for Whirlpool Findlay Division to continue its success. Related Book:

Focused Equipment Improvement for TPM Teams Marshall Institute, Inc., 1800 Tillery Place, Click HERE for more Suite i, Raleigh, NC 27604 1-800-637- 0120 information

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Operation’s Inspections Drive Reliability

Maintenance INTRODUCTION. Smurfit Stone’s Fernandina Beach facility Management continues on a long path to reaching world class reliability. In 1999, Articles the mill embarked on a courageous effort to revitalize its reliability program. The mill had a vision of being “world class” and set out on Reliability a course to achieve this goal. Discussion Forum At that time, the entire pulp & paper industry was going through a Christers paradigm shift. The market now dictated that only those facilities Krönika that focused on lowering cost would remain competitive in a global (articles in market economy. More tons out the door would no longer improve Monty Brown the facilities profitability. Reducing cost and improving operating Swedish) efficiencies was required to ensure that the Fernandina Beach facility Further information is Submit an would be a long term provider of linerboard. The mill’s management available by contacting article team realized that significant improvements in plant maintenance [email protected] and equipment reliability were critical to driving down the overall cost of manufacturing, and thus ensuring the facilities position in the market place.

Since 1999, many of the changes in the mill’s reliability effort have primarily been in the maintenance department. However, to achieve world class results, operations must be a core component of the reliability process. Recently, the mill has begun to incorporate operators in critical reliability functions.

The Fernandina Beach woodyard seemed like the perfect area to begin incorporating reliability principles. The woodyard management team was fully supportive of reliability concepts and principles, understood that operators could have a very positive impact to the maintenance process, and was willing to commit resources to implement new processes into the operators work flow.

THE MILL. Fernandina Beach is a fully integrated, ISO 9001:2000 Quality Management System certified mill with three paper machines. The mill was established in 1937 to produce kraft linerboard. Original production was 125 tpd of unbleached kraft pulp and has progressed through expansions and rebuilds to a production rate of 2850 tpd. Fernandina Beach operates a large woodyard receiving chips and round wood, batch and kamyr digester pulp mills, and a chemical recovery system including two recovery boilers, two power boilers, and two turbine generators.

RELIABILITY JUSTIFIED. The current state of the industry has led to new business practices in lieu of large capital expenditures to maintain the competitive edge. Additionally, traditional woodyards are being replaced with satellite chipping operations. A traditional http://www.idcon.com/articles/operationsBrown.htm (1 of 4) [5/15/2004 10:13:55 AM] IDCON Operations Inspections Drive Reliability industrial maintenance training, preventative maintenance program, on the job education, economical gain

woodyard process, such as Fernandina Beach’s, consists of very large mechanically driven equipment and numerous conveying systems that must withstand the destructive nature of wood raw materials. Therefore, to remain cost competitive with satellite facilities, it requires implementation of maintenance processes that counteracts the negatives of operating a traditional woodyard. The traditional woodyard must be highly reliable and proactive to keep the cost of running the business to a minimum.

In 1999, 70% of all the Fernandina Beach woodyard maintenance repairs were reactive in nature. The Woodyard was experiencing increased production and safety vulnerability, poor employee morale, lost production, and higher maintenance costs due to poor equipment reliability. At this stage, the woodyard was highly reactive; the decision-making process was being dictated by the equipment and not by the management team. The decision by Fernandina Beach to completely revisit and revitalize the entire mill’s preventive maintenance program in 1999 was a welcome site for the woodyard operating department.

IMPLEMENTATION. By 2001, changes in the mill reliability program were well underway. Condition Monitoring Routes (CMR) in the woodyard with mechanical maintenance technicians/millwrights was proving to be successful. Woodyard management recognized the value of the reliability process and began developing a strategy to incorporate the process at the operator level. The initial thought was that the process would not be successful if it was not driven at the operator level. This philosophy still holds true today.

The vision was to develop a world-class, employee driven process that would be measurable and achievable. This new way of conducting business would become the Fernandina Beach Woodyard maintenance doctrine.

The management steps used to implement a new equipment reliability doctrine was:

● educate the woodyard management and supervision on the concept of reliability ● conduct awareness meetings with the operators on reliability practices ● gain upper management support to acquire tools and re-direct resources ● train operators in proper equipment inspections ● develop operator condition monitoring routes

PROCESS. The woodyard wanted a short implementation cycle yielding immediate results. With the maintenance department having already established condition monitoring routes, it made good sense to use their existing program and make minor modifications to accommodate the operator requirements. Requirements of the operation’s CMR process included more frequent inspections, but with less detail than the mechanical CMR route. The mechanical inspector in the area essentially inspected every piece of equipment http://www.idcon.com/articles/operationsBrown.htm (2 of 4) [5/15/2004 10:13:55 AM] IDCON Operations Inspections Drive Reliability industrial maintenance training, preventative maintenance program, on the job education, economical gain

in the woodyard during an inspection cycle of one month. To be effective, woodyard operators could not inspect all equipment with the same level of detail. The woodyard reliability team* decided that operators would be more effective by focusing on critical equipment only.

* The woodyard reliability team consists of the woodyard department manager, the maintenance supervisor, a reliability maintenance supervisor, and two woodyard operations supervisors.

The woodyard reliability team developed a model to assess equipment criticality. Over 400 pieces of equipment were evaluated individually. The following categories were considered for each piece of equipment:

● Safety and Environment Impact ● Cost of Repair ● Impact to Production ● Quality Impact ● Availability of Parts ● In-line Spare ● Repair Time

The evaluation resulted in 83 of 400 items in the woodyard and all associated components deemed critical. Critical equipment was placed in one of the four condition monitoring routes listed below:

● Log System (16) ● Bark System (6) ● Chip System (17) ● Chip Thickness Screening (44)

In 2991, woodyard operators began performing inspections on critical equipment as part of their routine shift responsibilities. A typical inspection requires the operator to simply look, listen, and feel the equipment to assess condition. Operators have also been given additional tools to support the inspection process such as hand held computers and infrared temperature guns to facilitate capturing and recording bearing, motor, and other component temperatures.

RESULTS. Today, the Fernandina Beach woodyard maintenance process is a proactive process. The CMR process, with operator involvement, has resulted in a 70% reduction in reactive repairs since 1999. Reactive work for 2003 (as of July 2003) is down to 24% with a world class target of 5% as a goal. Recent data has shown operators are now responsible for identifying almost one-quarter of all critical equipment issues. During the same period, the woodyard’s maintenance budget has been reduced by almost one-third.

Additionally, recent woodyard case studies support suggestions that proactive repairs can be as much as five to ten times less expensive than repairs that are performed on a reactive basis; unplanned and unscheduled. They have learned that identifying equipment issues much sooner in a failure mode means less intrusive repairs requiring less time to complete. The Fernandina Beach woodyard is focusing http://www.idcon.com/articles/operationsBrown.htm (3 of 4) [5/15/2004 10:13:55 AM] IDCON Operations Inspections Drive Reliability industrial maintenance training, preventative maintenance program, on the job education, economical gain

on a path of more effective and efficient planned and scheduled work.

CONCLUSION. As most realize, implementing change can be difficult to execute. The Fernandina Beach Mill woodyard management team believed that gaining initial support from the employees would improve the odds of a successful change process. The team realized that being world-class would require operations personnel to take back ownership of their equipment. There has definitely been a culture change in the right direction.

It is understood that changes have to continue to take place in order to move closer to the goal of world-class. It is important to understand and communicate to the workforce and upper management that significant results are not expected overnight. Nevertheless, the impact to the workforce morale, safety and housekeeping has been positive and immediate. That alone justifies the implementation of the CMR process. The woodyard has seen some early and very significant improvements to equipment reliability, but the new relationship between operations and maintenance holds real promises for the woodyard to remain a long- term, low cost, provider of wood chips to the Fernandina Beach facility.

http://www.idcon.com/articles/operationsBrown.htm (4 of 4) [5/15/2004 10:13:55 AM] Total Productive Maintenance. TPM. Powerpoint Presentation

Imants BVBA The TPM (Total Productive Maintenance) Guide

Powerpoint Presentation

Consulting and Services

General Routine preventive maintenance has served us well over the past 40 years, but in order to maintain the equipment in optimal condition, new and progressive maintenance techniques need to be established.

It involves the cooperation of the equipment and process support personnel, equipment operators and the equipment supplier. They must work together to eliminate equipment breakdowns, reduce scheduled downtime, and maximize utilization, throughput and quality.

Total Productive Maintenance provides the methods to measure and eliminate much of the non-productive time, if implemented properly.

In order to help businesses implement TPM, Imants BVBA provides the Total Productive Maintenance Guide, a practical and comprehensive Powerpoint Presentation of all the aspects of TPM.

http://www.managementsupport.com/tpm.htm (1 of 4) [5/15/2004 10:14:16 AM] Total Productive Maintenance. TPM. Powerpoint Presentation

Table of Contents The Total Productive Maintenance Guide is a Powerpoint Presentation consisting of 38 slides :

1. TPM Definition (2 slides)

2. Origins of TPM

3. TPM principles

4. Eight Major Pillars of TPM

1. Autonomous maintenance (2 slides)

2. Equipment and process improvement and Overall Equipment Effectiveness (6 slides)

3. Planned maintenance

4. Early Management of New Equipment

5. Process Quality management

6. TPM in administrative and support departments

7. Education and training

8. Safety and environmental management

5. TPM implementation

1. 3 requirements for fundamental improvement

2. 12 implementation steps (15 slides)

6. TPM benefits

http://www.managementsupport.com/tpm.htm (2 of 4) [5/15/2004 10:14:16 AM] Total Productive Maintenance. TPM. Powerpoint Presentation

Target group This guide provides strategies, tools and techniques for both executives and managers in production, maintenance, engineering, and quality departments.

It also meets the growing needs of students studying business and especially production/operations and maintenance management.

Benefits The Total Productive Maintenance Guide will enable you to:

● adapt the presentation to your own needs ● show the presentation in your own company ● implement the proposed actions ● monitor the results ● communicate the knowledge of Total Productive Maintenance to your colleagues in your organization ● use it as a means to deepen your understanding of the topic

Customer Comments

Order You get the online version of the Total Productive Maintenance Guide (Powerpoint Presentation - 38 slides) for the low investment of US$ 14.95

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Spanish version: La Guía de Mantenimiento Productivo Total

http://www.managementsupport.com/tpm.htm (3 of 4) [5/15/2004 10:14:16 AM] Total Productive Maintenance. TPM. Powerpoint Presentation

Other Guides New: The Integrated Business Improvement (IBI) Guide

The Reliability Centered Maintenance (RCM) Guide

The ERP Guide

The Lean Manufacturing Guide

The Maintenance Management Guide

The Supply Chain Management Guide

The Advanced Planning and Scheduling (APS) Guide

The Bar Code Guide

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Tel: +32 11 541278 | Fax: +32 11 552482 | e-mail:[email protected]

http://www.managementsupport.com/tpm.htm (4 of 4) [5/15/2004 10:14:16 AM] http://membres.lycos.fr/hconline/5S/fives.htm Principles of 5S best in 1024x800 HOME Maintenance Portal 5S Portal French version AUTHOR Last update: December 1st, 2003

Efficient work and quality require clean environment, safety and Hints to 5S discipline. 5S are simple, effective rules for tidiness. The 5S principle is gradual and necessarily in that order. Principle of 5 S 5S are for everybody, it is The 5S are prerequisites for any improvement program. As waste is potential gain, so eliminating waste is a gain. hopeless expectation for 5S Philosophy focuses on effective work place organization, simplifies work environment, reduces waste while improving subordinates to follow 5S if quality and safety. manager class does not comply to There is no hope for efficiency or quality improvement with dirty work place, waste of time and scrap. it.

The five S stand for the five first letters of these Japanese words: 5S show efficiency in time, transforming the physical environment of work area and Meaning spirit of all employee levels. Seiri Sorting Out All this seems obvious? Looks easy? Seiton Systematic Arrangement Of course there is nothing really Seiso Spic and Span new, but before saying it is so simple or even doute its efficiency, Seiketsu Standardizing try to set up 5S for yourself, for your unit. Shitsuke Self-discipline You will see difficulties and reluctance, so called resistance to change, the natural tendency to Calling these principles the "5S" is a good way to remember their meaning and content. return to the status quo and the good old way.

What are 5S? After succeeding in setting up 5S, don't forget to keep them alive!

Seiri

Sorting, keep the necessary in work area, dispose or keep in a distant storage area less frequently used items, unneeded items are discarded.

Seiri fights the habit to keep things because they may be useful someday. Seiri helps to keep work area tidy, improves searching and fetching efficiency, and generally clears much space. Seiri is also excellent way to gain valuable floor space and eliminate old broken tools, obsolete jigs and fixtures, scrap and excess raw material. Read more about 5S and related topics by checking the 5S portal

http://membres.lycos.fr/hconline/5S/fives.htm (1 of 3) [5/15/2004 10:14:39 AM] http://membres.lycos.fr/hconline/5S/fives.htm Seiton

Systematic arrangement for the most efficient and effective retrieval. A good example of Seiton is the tool panel. Effective Seiton can be achieved by painting floors to visualize the dirt, outlining work areas and locations, shadow tool boards. For improving changeover time with SMED or reduce machine downtime through Total Productive Maintenance (TPM) it is necessary to have tools at hand. So a specific mobile tool cart was designed. An other example of Seiton are "broom carts". As cleaning is a major part of 5S we custom made carts to hold brooms, mops and buckets. Several carts have specific locations and all employees can find them.

Seiton saying would be: "A place for everything and everything on its place."

Seiso

Cleaning. After the first thorough cleaning when implementing 5S, daily follow-up cleaning is necessary in order to sustain this improvement. Cleanliness is also helpful to notice damages on equipment such as leaks, breakage and misalignment. These minor damages, if left unattended, could lead to equipment failure and loss of production. Regular cleaning is a type of inspection. Seiso is an important part of basic TPM; Total Productive Maintenance and Safety matter through cleanliness is obvious.

Seiketsu

Standardizing. Once the first three S have been implemented, it should be set as a standard so to keep these good practice work area. Without it, the situation will deteriorate right back to old habits. Have an easy-to-follow standards and develop a structure to support it. Allow employees to join the development of such standards.

The 3 first S are often executed by order. Seiketsu helps to turn it into natural, standard behavior.

Shitsuke

Finally, to keep first 4 S alive, it is necessary to keep educating people maintaining standards. By setting up a formal system; with display of results, follow-up, the now complete 5S get insured to live, and be expanded beyond their initial limits, in an ongoing improvement way; the Kaizen way.

The effect of continuous improvement leads to less waste, better quality and faster lead times.

http://membres.lycos.fr/hconline/5S/fives.htm (3 of 3) [5/15/2004 10:14:39 AM] June 00

Site Updated Strategic Work Systems Banner 5/10/2004

Visual Systems Supplies June 2000

Click below for our price list & So What Do You Know order form. About Your Overall Equipment Effectiveness?

By Robert M. Williamson, president of Strategic Work Systems

Equipment performance and reliability have become major concerns as businesses reorganize, downsize, and aggressively pursue “lean” principles. Is your equipment doing what it is supposed to do, first time, every time? What are

the causes of poor performance? What should you focus on?

Measuring and improving equipment performance is becoming a hot topic in Click here to see our full line many facilities, manufacturing plants, and processing plants. So, what do you of equipment marking know about your overall equipment effectiveness (OEE)? The basic measure supplies associated with Total Productive Maintenance (TPM) has been OEE. It incorporates three basic indicators of equipment performance and reliability: What’s New ● Availability or uptime (downtime: planned and unplanned) ● Performance efficiency (actual vs. design capacity) Feature Article Want a Successful ● Rate of quality output Maintenance Program? Focus on Results! OEE is not an exclusive measure of how well the maintenance department works. The design and installation of equipment as well as how it is operated and

MARCON 2004 Presentation maintained affect the OEE It measures both efficiency (doing things right) and Files effectiveness (doing the right things) with your equipment.

Here is an example on how OEE is figured for a critical piece of equipment:

● Running 70 percent of the time (in a 24-hour day) Site Highlights ● Operating at 72 percent of design capacity (flow, cycles, units per hour) ● Producing quality output 99 percent of the time

When you factor the three together (70% availability x 72% efficiency x 99% quality), the result is an overall equipment effectiveness rating of 49.9 percent. The OEE rating truly reflects how well the equipment is loaded and doing what it is supposed to – in this case less than 50 percent. Running at 55 percent OEE meets plant requirements.

http://www.swspitcrew.com/html/june_00.html (1 of 3) [5/15/2004 10:14:48 AM] June 00

Library: A new article each Given the OEE data, we can then determine the “cost of unreliability” or poor month, a link to our archives, equipment performance. This is where it gets interesting. For example, a five plus suggested reading percent decline in OEE may have led to 500,000 units not produced in a year. And at a sales price of $12 per unit, the cost of unreliability is $6,000,000 of lost

Services: How can we help sales (revenues). This helps make a strong business case for improving the care you strive for world class? and upkeep of the critical equipment in question.

Who We Are: Meet our pit The OEE rating for critical equipment provides a relative comparison or “report crew and read our Credo. card” on equipment performance and how well our maintenance and operations improvement activities are doing. The real use of OEE comes by using the factors (availability x efficiency x quality) and the actual losses to determine root cause Links: Visit some of our favorite sites. and corrective action.

So, back to our example. What caused the five percent decline in OEE in the Home: An overview of Strategic Work Systems example above? What changed? This is where the factors of OEE become more important than the percent OEE itself. By tracking and trending the factors of OEE (data), one can quickly spot whether the machine experienced more Seminars downtime (planned or unplanned), or was running at a slower pace or minor stops, or produced more defects. Improper or inefficient operation can cause Overview lower availability (setups, tool, or part changing) as can improper maintenance (breakdowns). Root cause analysis begins by focusing on the type and extent of loss, not the OEE percentage rating. TPM

Here are some additional ways to think about OEE in a variety of equipment Precision Maintenance settings:

How to Reach Us Individual machine: The performance of the machine is only compared to itself over time (historical trending). The factors of OEE should be tracked and trended to observe changes in performance. Call (864) 234-3100 Fax (864) 234-3101 E-mail Integrated manufacturing cell: Regardless of the individual machine performance, the entire multi-machine cell must function as a single unit. OEE for the cell is a good relative performance comparison. Multiple product sizes dictate different production rates and therefore OEE ratings. Availability, efficiency, and rate of quality for the individual machines in the cell allow the focus on root causes.

Discreet manufacturing: Individual machines and integrated cells must function Click here for info in a variety of combinations to produce many different types and sizes of on our mailing list products. In lean manufacturing, synchronous manufacturing, and plants with pull scheduling, production flows become leveled and depend on TAKT time, the rate of use of the customer. OEE can be misleading. However, the factors of OEE - Recommend This availability, efficiency, and rate of quality - become indicators of where and what Page to a Friend type of improvements should be made.

Process plants: A process stream must perform as a whole, similar to an integrated manufacturing cell. OEE, or “overall process effectiveness” (OPE) is a

http://www.swspitcrew.com/html/june_00.html (2 of 3) [5/15/2004 10:14:48 AM] June 00

good relative performance comparison. The factors of OEE should be tracked and trended to observe changes in performance of critical equipment in the process stream. In some processes, quality losses of “yield” and losses associated with transitions from one product to another become big opportunities for improvement.

Facilities: Utility systems in schools, hospitals, and commercial buildings (HVAC, chilled water, steam, refrigeration, compressed air, etc.) typically function as individual machines or processes in support of a facility, and possibly other machines. In these cases, OEE ratings on the critical machines should be tracked and trended to observe changes in performance. The factors of OEE should be tracked: Availability measures uptime. Efficiency measures flow rates, volumes, etc. Quality measures pressures, temperatures, etc.

Overall Plant Comparisons: While it may be tempting to measure and report “Overall Plant Effectiveness,” it may be of little use when answering the questions “How well are we doing?” and “Where do we need to improve?” And comparing OEE out of context proves little.

Remember: OEE is just a number for relative comparison of equipment performance. The real benefits come from using the factors of OEE, which lead to root cause analysis and eliminating the causes of poor performance. It’s all about collecting, trending, and analyzing the right data on your critical equipment performance and reliability. Learn more about OEE and reap the benefits of systematically identifying and eliminating the causes of poor performance in your plant or facility.

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http://www.swspitcrew.com/html/june_00.html (3 of 3) [5/15/2004 10:14:48 AM] Accomplishments through TPM in the real world

Accomplishments

By Enrique Mora

For some years now (almost 40) I have been in very close contact with the industrial maintenance activity.

I have understood that we should always look for new formulas to make it simpler better and more efficient. It was until I started looking at TPM that I felt the real "Click".

The involvement of the customers is so important, perhaps that is the key to success in all the activities.

The companies I have been working with are experiencing impressive set up time reductions, machines that are doing what they never did, savings in the processes and improvement in the final product.

Mr. Dyer from Productivity Inc. is proud as well of the results achieved by some of the companies that have implemented TPM. In an interview recently published on the Internet he said: "Copeland Industries, for example, implemented a TPM program in 1989. Since that time, the company has recorded a 57 percent improvement in manufacturing cycle time, scrap and rework costs have declined by 72 percent, manufacturing costs are down 60 percent, plant operating costs declined by $2 million in just 18 months and total downtime for maintenance was at an astounding 1.9 percent,.."

Some companies with old machines were having poor performances from them. I have the case of a pipe bender that had never been able to bend schedule 80 steel pipe in short radius. After the TPM effort, with new seals, improved clamps and fine tunings in the hydraulic system, it does bend it...

Mr. Floyd an important executive from Exxon said one of the most impressive measures in his mind is Exxon’s process capability index, which is currently 1.75 up from 0.61 in 1991.

That, coupled with a reduction in Exxon’s maintenance costs to 1.9 percent of

http://www.tpmonline.com/services/tpmaccomps.htm (1 of 2) [5/15/2004 10:14:55 AM] Accomplishments through TPM in the real world replacement costs, has illustrated how effective TPM can be in a process industry.

Examples can be counted by the hundreds, but the real question is:

Are you getting the good results that you expected?

If your answer is no, or you have not determined yet what practices should be adopted, we invite you to get some external help.

Enrique Mora has been successfully involved in the design and implementation of this kind of programs for more than 30 years.

E.M. Consulting can visit your plant and tell you if TPM is for you, what can be realistic to expect, and how long it may take. Do not expect any outrageous fees. Also for free you can submit all your questions... through E-mail... Contact him, click here!

http://www.tpmonline.com/services/tpmaccomps.htm (2 of 2) [5/15/2004 10:14:55 AM] 5S one of the philosophies for Lean Mfg. Las 5S's una de las filosofías de Manufactura Esbelta

Essential in the Lean Manufacturing Structure is The "5S" Philosophy

This is the finest piece of easy information about this subject that I have ever seen. The 5"S"s are explained here as a very simplified but thorough and feasible process. I am sure that you will find it excellent! Thank you Todd.

Enrique Mora

Anyone who has recently opened a new machine shop has certainly had these thoughts: How can I improve efficiency, work organization, quality, safety and housekeeping and protect my investment at the same time? Todd Skaggs, President of Metaltek Mfg. Inc., decided that the 5S process could effectively impact the way his company did business.

Based on Japanese words that begin with ‘S’, the 5S Philosophy focuses on effective work place organization and standardized work procedures. 5S simplifies your work environment, reduces waste and non-value activity while improving quality efficiency and safety.

Sort – (Seiri) the first S focuses on eliminating unnecessary items from the workplace. An effective visual method to identify these unneeded items is called red tagging. A red tag is placed on all items not required to complete your job. These items are then moved to a central holding area. This process is for

http://www.tpmonline.com/articles_on_total_productive_maintenance/leanmfg/5sphilosophy.htm (1 of 4) [5/15/2004 10:15:07 AM] 5S one of the philosophies for Lean Mfg. Las 5S's una de las filosofías de Manufactura Esbelta

evaluation of the red tag items. Occasionally used items are moved to a more organized storage location outside of the work area while unneeded items are discarded. Sorting is an excellent way to free up valuable floor space and eliminate such things as broken tools, obsolete jigs and fixtures, scrap and excess raw material. The Sort process also helps prevent the JIC job mentality (Just In Case.)

Set In Order (Seiton) is the second S and focuses on efficient and effective storage methods.

You must ask yourself these questions:

1. What do I need to do my job? 2. Where should I locate this item? 3. How many of this item do I need?

Strategies for effective Set In Order are painting floors, outlining work areas and locations, shadow boards, and modular shelving and cabinets for needed items such as trash cans, brooms, mop and buckets. Imagine how much time is wasted every day looking for a broom? The broom should have a specific location where all employees can find it. "A place for everything and everything in its place."

Shine: (Seiso) Once you have eliminated the clutter and junk that has been clogging your work areas and identified and located the necessary items, the next step is to thoroughly clean the work area. Daily follow-up cleaning is necessary in order to sustain this improvement. Workers take pride in a clean and clutter-free work area and the Shine step will help create ownership in the equipment and facility. Workers will also begin to notice changes in equipment and facility location such as air, oil and coolant leaks, repeat contamination and vibration, broken, fatigue, breakage, and misalignment. These changes, if left unattended, could lead to equipment failure and loss of production. Both add up to impact your company’s bottom line.

Standardize: (Seiketsu) Once the first three 5S’s have been implemented, you should concentrate on standardizing best practice in your work area. Allow your employees to participate in the development of such standards. They are a valuable but

http://www.tpmonline.com/articles_on_total_productive_maintenance/leanmfg/5sphilosophy.htm (2 of 4) [5/15/2004 10:15:07 AM] 5S one of the philosophies for Lean Mfg. Las 5S's una de las filosofías de Manufactura Esbelta

often overlooked source of information regarding their work. Think of what McDonalds, Pizza Hut, UPS, Blockbuster and the United States Military would be without effective work standards.

Sustain: (Shitsuke) This is by far the most difficult S to implement and achieve. Human nature is to resist change and more than a few organizations have found themselves with a dirty cluttered shop a few months following their attempt to implement 5S. The tendency is to return to the status quo and the comfort zone of the "old way" of doing things. Sustain focuses on defining a new status quo and standard of work place organization.

Once fully implemented, the 5S process can increase moral, create positive impressions on customers, and increase efficiency and organization. Not only will employees feel better about where they work, the effect on continuous improvement can lead to less waste, better quality and faster lead times. Any of which will make your organization more profitable and competitive in the market place.

Todd Skaggs is the President/CEO of Metaltek Mfg. Inc. located in Hodgenville, KY. Metaltek is a precision CNC machining and metal fabrication facility serving the manufacturing sector nationwide. Mr. Skaggs can be reached at 270.358.0202 or [email protected]

LEAN KAIZEN EVENTS JUST IN THE 8 MANUFACTURING A TOOL FOR TIME WASTES BASICS IMPLEMENTATION ELEMENTOS DE EVENTOS KAIZEN MANUFACTURA HERRAMIENTA DE JUSTO A LAS 8 ESBELTA IMPLEMENTACIÓN TIEMPO PÉRDIDAS

http://www.tpmonline.com/articles_on_total_productive_maintenance/leanmfg/5sphilosophy.htm (3 of 4) [5/15/2004 10:15:07 AM] 5S one of the philosophies for Lean Mfg. Las 5S's una de las filosofías de Manufactura Esbelta

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http://www.tpmonline.com/articles_on_total_productive_maintenance/leanmfg/5sphilosophy.htm (4 of 4) [5/15/2004 10:15:07 AM] Not to Implement is More Expensive - Es Mas Caro No Implementar TPM

The Cost of NOT El Costo de NO Implementing TPM Implementar TPM by Enrique Mora Enrique Mora

One of the most frequent concerns among the Una de las preocupaciones más frecuentes entre los dueños manufacturing plant owners, is: What is the cost de plantas de manufactura es: ¿Cuál será el costo de of implementing TPM? Dozens of people have implementar TPM? Docenas de personas me preguntan asked just that question in my presentations and my eso en mis presentaciones, y mi respuesta es siempre la answer is always the same: misma:

The cost of implementing TPM is a formula where the El costo de implementar TPM es una fórmula cuyos elementos components are already in plant: componentes ya existen en cada planta:

● Maintenance programs in place ● Programas de mantenimiento existentes ● Age of the equipment ● Edad del equipo ● Pace to be taken ● Ritmo de Implementación

Some plants have excellent programs in place and have Algunas plantas tienen excelentes programas de kept their equipment in very good shape, so the cost for mantenimiento y su equipo está en muy buen estado, su them will be lower than for those who have a bad costo será menor que para aquéllas plantas con pobres o program or none in place. ningunos planes de mantenimiento.

Old equipment sometimes will face the high cost of El equipo antiguo a veces puede requerir de repuestos que parts if attainable. por escasos resultarán caros, si es que los hay.

If you want a fast paced implementation, the cost per Si se quiere una implementación rápida, el costo anual se year will be higher. incrementará.

Facing reality: The cost of implementing TPM is not Enfrentemos la realidad: El costo de implementar el TPM no important. Compare it to a necessary surgery. Then you es importante, comparémoslo con una cirugía necesaria. will think: Entonces la idea cambiará: What is the cost of NOT ¿Cuál es el costo de NO implementing TPM? implementar TPM?

At this crucial point of global competition, the En esta etapa crucial de la competitividad global, el implementation of Total Productive Maintenance is not implementar el Mantenimiento Productivo Total ya no es un a matter of liking it or following the fashion. While TPM asunto de ver si nos parece conveniente implementarlo o no. was in the 60's just an innovative thing, today it has Tampoco es algo que "está de moda". Mientras al nivel de sus http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/noimplement.htm (1 of 2) [5/15/2004 10:15:21 AM] Not to Implement is More Expensive - Es Mas Caro No Implementar TPM turned into a survival strategy. orígenes el TPM era algo simplemente innovador, hoy se ha convertido en una estrategia de supervivencia. Not very long ago I finally had the opportunity to implement on a machine after several months when the No hace mucho logré hacer implementación en una máquina production people could not afford to release it for us. luego de varios meses en que no fué posible que me la Two weeks later the machine went back in production soltaran para llevar a cabo el proyecto. Dos semanas performing at its full capacity, almost double of what it después, la máquina estaba de regreso en producción y a su was working before the project. The moral here is: for plena capacidad, casi el doble de la que tenia antes de que la each week that the implementation was procrastinated, interviniésemos. La moraleja aquí es que por cada semana de the product of that machine had a cost of almost double retraso en la implementación, el costo de las partes than it has now. For some products and trades, this producidas estuvo a casi el doble de lo razonable. En algunas kind of cost increase can represent the temporary or empresas, un efecto así puede representar la pérdida de definitive loss of market share. mercado en forma temporal o definitiva.

TPM is capable of bringing a machine back to original TPM es capaz de traer al equipo a una condición igual que condition and even better. Let us not waste that cuando era nuevo o aún mejor. No desperdiciemos una opportunity, because the cost of postponing a decision oportunidad así, pues el costo de posponer la decisión que that we will have to make sooner or later, can be tarde o temprano deberemos tomar, podría ser excesivo. excessive. I am fully convinced that the loses for each Estoy convencido de que por cada día de aplazamiento, day of delay are out of our imagination. Look for tenemos pérdidas incalculables. Infórmese e inicie cuanto information and get started, one machine at a time. The antes, una máquina cada vez. Los resultados no se dejarán results will come to make you proud. esperar.

TPMonLine has received This page last updated on

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http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/noimplement.htm (2 of 2) [5/15/2004 10:15:21 AM] Keys to a Successful TPM or Lean Implementation

The Right Ingredients for a Successful TPM or Lean Implementation

by Enrique Mora

Just a few days ago I received a call from Mark Hoffman that made me think a lot... Let me share it with you...

Given the fact that only 10% or less of companies succeed at implementing TPM (and other Lean Manufacturing Practices, I would add), what are the main factors behind that success? Actually, Mark Hoffman is only interested on TPM, but my experience has shown me that it applies to all of the other practices as well.

What a good question!

All implementers want our projects to be a success. So, what are the factors that really help this to happen? We will also ask the opposite question: What are the factors that keep TPM (and other lean projects) from succeeding?

Positive Factors

● Top management support is perhaps the concrete factor in the teams with good results. Some other positive factors will be: ● Good training at all levels of the organization Let us remember: TPM and Lean Manufacturing disciplines, while technical, are more cultural. Everyone in the organization must receive a lot of information on the new culture. This awareness is crucial to get all the people tuned at the same frequency. ● Vision and Mission Statements should include concepts like: Our people are the single most valuable asset in the company. All employees are our associates, or... are responsible for our success, etc.

http://www.tpmonline.com/articles_on_total_productive_maintenance/management/keys2success.htm (1 of 5) [5/15/2004 10:15:28 AM] Keys to a Successful TPM or Lean Implementation All other actions will have to support such statements.

Management must be ready to complete the move all the way from the old image of "power from authority" to "respect and admiration from true leadership".

Job descriptions (at least for new hires) should also be adjusted to reflect the new culture.

● A good PM program already in place: It is necessary to have a good Preventive Maintenance program in place, so that we count on clear identification of each piece of equipment and have some history. Also helpful is any documentation that we find available on the performance of each machine and the chronic failures or problems. ● Full information about equipment performance: To begin a project, we research all possible information about the actual, expected and designed performance of it. Some of this may be documented in work orders. I strongly recommend establishing a very good communication with the "owners". That is the operator of the machine, the area supervisor(s) and/or manager(s). ● Good communication skills of the TPM coordinator or Continuous Improvement Manager: This is the key person in the success of the program implementation. The coordinator is in charge of creating a good image for the new philosophies. His/her mission is not only to train the implementer teams, but also to educate everyone else in the plant. He/she, has to become an expert in this culture and explain it to anyone who wants to listen. He/she must develop a creative broadcasting of the progress. ● Full time person(s) assigned to those tasks: The lean philosophies require continual dedication and training. This person will have to attend a minimum of one seminar each year, (more than one if possible). Many companies fail when they decide to just split the time of someone who is already in charge of some other assignment http://www.tpmonline.com/articles_on_total_productive_maintenance/management/keys2success.htm (2 of 5) [5/15/2004 10:15:28 AM] Keys to a Successful TPM or Lean Implementation or task. ● Follow UP: Once a project is delivered back to the "owners", we must be aware that TPM has just begun for that particular machine or system. The other 99% of the success will depend on the permanent communication that the coordinator establishes with the operators. We must make it clear that we are there to listen to them, they ARE our customers. The few weeks following a project will be crucial in terms of creative improvements to the machine and its area. This follow up builds up the confidence that our customers feel towards the project and the prestige of the program in general. ● Passion! Indeed this and most other activities must be supported by a passionate belief and dedication in order to really succeed.

From the previous lines we can also define some of the obstacles that the project finds just in the lack of support, dedication or discipline. Some other factors can also undermine the program:

Negative Factors:

● Middle management: We have found that middle managers, supervisors, even some lead people, feel threatened in their positions by these changes. Again this is a matter of culture shift. These people must be shown the advantages of sharing their knowledge and responsibility with the production operators. ● Maintenance Technicians: For years, maintenance has been conceptualized as a repairing force. Now we must focus on maintaining the equipment in normal operating conditions thus preventing failure. Many of the technicians feel that keeping some technical secrets makes them more valuable or their jobs more secure. This is not true. Under the new way of conducting business, the more the operators get involved in the maintenance tasks, the better the technicians can apply their expertise to higher level operations. These include: equipment re-engineering, predictive maintenance, area re- http://www.tpmonline.com/articles_on_total_productive_maintenance/management/keys2success.htm (3 of 5) [5/15/2004 10:15:28 AM] Keys to a Successful TPM or Lean Implementation designs, installation and facilities improvements. ● Concerned Production / Mfg. / Engineering: Must be made clear that TPM or other of these disciplines aren't an extra burden on production, manufacturing or engineering, but are instead, ways to ease the accomplishment of their own goals.

As we can see, the success of any lean implementation is for the most part a Common Sense application. Devote the time and effort to build the new culkture and the results will show up immediately and at long term...

TPMonLine has received This page last updated on

11/04/02 06:14

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File #

http://www.tpmonline.com/articles_on_total_productive_maintenance/management/keys2success.htm (5 of 5) [5/15/2004 10:15:28 AM] Total Productive Maintenance Case Study a Total Productive Maintenance Case Study

a provided by the Marshall Institute, Inc. MRC Bearings' TPM Journey: From Totally Painted Machines to a Taking Pride in Our Machines

Many maintenance related In 1996 MRC Bearings, a unionized aerospace industry supplier, products are available to recognized it had a problem. They were behind on their orders. Their you in our Products customers were pushing for shorter lead times and cost reductions. Showcase Approximately eighty percent of their maintenance hours were dedicated to emergency work orders. In October of 1997 over one For other articles related to this topic thousand, six hundred and sixty hours were consumed by unplanned visit our Reference maintenance in just one area. Ten months later that number fell to less Library. than thirty hours. That's over a 98% decrease. In another area they were able to achieve almost a 99% decrease in the number of unplanned maintenance hours in an eight-month period. Greg Folts, Manager of Continuous Improvement at MRC attributes their top remarkable success to having a hardworking, dedicated maintenance team and implementing a Total Productive Maintenance (TPM) program. Need more training? "We started slow, beginning with a small area that was critical to our process but was experiencing chronic problems," said Folts. "At first, a We've got information about lot of people were skeptical and not really interested in getting involved Total Productive with TPM," he said. "We had a core of people who were excited about Maintenance TPM and we enlisted the help of people outside of our organization to training and trade work with us," Folts said. MRC worked with Preston Ingalls, President of shows available to Marshall Institute, to organize their TPM efforts. He continued, "Preston you if you visit our helped us get started, but he was also our best cheerleader. He got our Events Calendar folks fired up about TPM." One of MRC's customers, Pratt-Whitney, also supported their efforts by facilitating MRC's first TPM event and sharing their TPM practices with MRC. MRC began with a week-long TPM event. Folts explained they would top begin by cleaning, inspecting, lubricating, and performing corrective work on a piece of machinery. Once a machine was cleaned, it would be painted. At first, people were reluctant to participate in TPM events. As Browse the . . . time went on, people began to notice what improvements were being Maintenance accomplished under the TPM events. "In fact, the same people that were Resources hesitating in the beginning were suddenly asking when their machine Bookstore would be scheduled for a TPM event," Folts said.

http://www.maintenanceresources.com/ReferenceLibrary/ezine/tpmcasestudy.htm (1 of 5) [5/15/2004 10:15:42 AM] Total Productive Maintenance Case Study

where you'll find books on total productive maintenance.

Rick Staples, an Electrician that has been involved with TPM since it's inception said, "The physical changes are easy to see. Our machines are more reliable, the area is cleaner and a lot more pleasant atmosphere to work in. Other changes, to those of us that work here every day, are not as easily detected. For instance; several people who were totally against TPM at the start, have now willingly participated in TPM workouts or equipment improvement teams. Another individual, who one told me to keep my TPM away from his machines, now is a fully trained TPM Coordinator in his area. It's these types of things that truly amaze me. The culture change is slow, but it's happening." MRC formed Equipment Improvement Teams (EITs) to work on resolving equipment-related issues. Folts credits the EITs with a success that was critical in their adoption of TPM. He explained they had a piece of equipment with chronic problems. It was breaking down monthly requiring three or four days each time to fix. He explains, "We were really frustrated by this problem, we kept fixing it only to see it break down again."

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The Equipment Improvement Team took on this problem and discovered the original manufacturer had used a sub-spec coupling on a drive unit. The problem was solved by upgrading to the proper coupling. This fix alone increased the efficiency on this piece of equipment by sixteen percent. "By taking the time to find the root of the failures, rather than just fixing the symptoms, we were able to solve this problem. In the years following this repair, the problem was completely eliminated. That success showed a lot of people in the company that TPM can make everyone's daily life easier as well as improving productivity," Folts said.

After the initial success, followed by eight TPM events, MRC expanded their TPM efforts to their second facility. They created a TPM Steering Committee at their second site and also created a Policy group to coordinate the efforts of both facilities. The President of MRC Bearings, Bengt Nilsson joined the Policy group as an active member. "Having the company president working with us to drive TPM sent a clear message to everyone that this was not just another flavor of the month program," said Folts.

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Don Russell was then solicited to assist in driving the process as the TPM Coordinator. "We have been very fortunate to have fantastic support from both management as well as our U.A.W Union personnel," said Russell. In a recent MRC company newsletter, President Nilsson is pictured shoulder to shoulder with the TPM Area Coordinators. TPM at MRC has been described as one of the most successful co-management programs ever started at MRC. Mr. Nilsson said, "I am very pleased and proud of how the whole organization, after the initial skepticism and hesitation, enthusiastically embraced the TPM concept. It is of utmost importance to have reliable and well maintained machinery in order to serve our customers well and to get on-time deliveries. A well developed TPM program is one of the cornerstones in our drive for manufacturing excellence." MRC trained ten TPM Area Coordinators who are dedicated to TPM one week each month. These TPM Coordinators organize TPM events in their areas, also lead EITs, and make sure the process keeps working. MRC has begun to create full-time TPM teams. One such team, comprised of Jeff Franklin, an Electrician and Jim Klugh, a Mechanic, and Jeff Johnson, an Operator, were able to correct a long-standing equipment problem which reduced the scrap produced by that equipment to almost zero. Folts and Russell attribute their success in implementing TPM to seven things. Russell said, "We realized early on that we couldn't do it all. So we identified a few areas that we felt were key, we did those things, and we did them well." The areas that MRC focused on were:

Preventative maintenance

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1. Putting predictive maintenance process in place (i.e., vibration analysis equipment) 2. Cleaning the machines, resulting in inspection 3. Creating standards on the equipment for cleaning, lubrication, and daily checks 4. Collecting data on downtime 5. Creating Equipment Improvement Teams 6. Creating TPM Area Coordinators

From this experience, Russell suggests organizations beginning TPM programs start small and keep it simple. Did MRC learn any lessons implementing TPM? Folts said, "We learned that training is a key to being successful with TPM. We did some initial TPM awareness training for the organization, about one week of training with the operators, and some for the mechanics. But, looking back we could have had quicker success if we had done more training." Folts also credits their success to the support of their management, the U.A.W. union, the hard work of the people at MRC, involvement of Marshall Institute, and the support of their customers. "Ultimately this is a people issue and we are lucky to have the right people involved," he said. Thinking back about the initial resistance to TPM, Don Russell laughs and says, "At first a lot of folks here defined TPM as 'Totally Painted Machines'. Now I can say we all define TPM as 'Taking Pride in our Machines'."

For more information about industrial customized training and consulting top visit Marshall Institute's website at http://www.marshallinstitute.com

If you have any comments about the article you have just read and you would like to share them with us at TWI Press, please feel free to email us by clicking on the email button below.

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http://www.maintenanceresources.com/ReferenceLibrary/ezine/tpmcasestudy.htm (5 of 5) [5/15/2004 10:15:42 AM] TPM: Another Three-Letter Program or a Real Improvement Process?

by Preston Ingalls, President, Marshall Institute TOTAL PRODUCTIVE MAINTENANCE... three words that are beginning to dominate the American worker's vocabulary. Is it another trendy program in American management or a true means to actually improve operations? Some organizations will treat TPM as just another program or as one of many possible treats on a "smorgasbord" of sampling and discarding. For the most part, organizations are beginning to see TPM for what it is - a systematic means to improve quality, delivery, and reduce costs. TPM is accomplished by getting the largest assets of the organization, people and equipment, to work together. TPM is composed of five major elements: Reliability Engineering (maintenance-free design); Autonomous Maintenance (operator involvement); Training (upgrading the skills and knowledge of operators and maintenance personnel); Maintenance Excellence (interval based servicing, planning, scheduling, and condition-based monitoring); and Equipment Improvement Teams (problem solving groups). TPM can accomplish more effectively what other quality or maintenance improvement efforts cannot. The success of TPM comes from the synergy of all these elements working together. Once the elements of TPM are understood and working together, goals and vital phases must be defined. The goals of TPM are to move towards zero breakdowns, zero defects, and lower costs. To accomplish these goals, the three phases of the equipment's life span must be properly observed. The first phase is the acquisition or start-up stage. Improvements consist of designing the best possible equipment, manufacturing it properly, and installing it correctly. Life Cycle Costs (LCC) can be reduced by using Reliability Engineering to properly design equipment for reliability and accessibility. One must take into consideration component life expectancy, ergonomics of operator usage, and ease of accessibility for maintaining the equipment. Since 80-90% of the costs of maintaining a piece of equipment is predetermined by the way it was designed and manufactured, there are enormous opportunities to reduce those costs by doing a goo d job up front and by applying Reliability Engineering concepts. Input by managers and engineers working with operators and maintenance personnel is critical. The second phase, the operational stage, deals with operating and maintaining the equipment in the best manner possible. Autonomous Maintenance and training play important roles at this stage. Neglect and abuse can be minimized by ensuring operators have the best skills to operate and set up their equipment. In addition to maintaining basic care of the equipment by keeping it clean, properly lubricated, and physically secured, the operator can serve an important and active role in providing on-site detection by looking for signs of deterioration. Spotting and responding to deterioration in equipment infancy can prevent breakdowns.

MARSHALL INSTITUTE WWW.MARSHALLINSTITUTE.COM 1 The last phase, the wear-out stage, is the period when the equipment's performance is affected by wear and tear. By using Preventive and Predictive Maintenance (PPM), the effects of deterioration can be minimized. A good Preventive Maintenance program provides interval or timed servicing of the equipment so the components can be replaced as they wear. Cleaning, lubricating, adjusting, inspecting, repairing, replacing, and testing can decrease deterioration. Predictive Maintenance allows the use of technology to monitor wear-out. Coupled with human conditional monitoring (on-site operator inspection), a proactive response to prevent failures can be developed. The best time to address a big problem is when it is small. Corrective maintenance is important since correctly diagnosing and fixing problems is key to minimizing the effects of wear. Equipment Improvement Teams (small group activities) with cross-functional membership should be applied during all three stages. These teams help in the design of new equipment, assist the operator in conducting basic care and inspection activities, and identify and eliminate the causes to equipment losses. Training is applied at all three stages to ensure that everyone involved with the operating and servicing of equipment has high skills and knowledge. Part of the team charge is to help elevate the equipment and optimize its performance by tracking and improving its Overall Equipment Effectiveness (OEE). Although Equipment Improvement Teams are an integral part of successful TPM and equipment life span, the key to the success of TPM is management support. TPM is not a maintenance program. It is a plant-wide process involving everyone. Maintenance is a key player in successful production, engineering, and management. Therefore, all levels of management have to demonstrate commitment to giving resources, time, and patience to allow TPM to take affect. Most machine failures do not occur by chance; most failures are either caused by or indicated by deterioration or drift in operating condition, conditions that can often be observed or measured. The ability to eliminate breakdowns comes from preventing them. Eliminating breakdowns means detecting signs of deterioration or drift. Almost 75% of all breakdowns can be prevented by having the operator closest to the equipment cleaning and inspecting it on a regularly planned basis. Breakdowns can be prevented only if we can spot them in the early stages of deterioration. Spotting them means detecting changes in operating conditions or watching for "telltale" trends that point to future problems. The remaining 25% of breakdowns can be detected by maintenance craftspeople conducting regularly scheduled Preventive Maintenance tasks and applying Predictive Maintenance technology. Modern technology has greatly improved our ability to monitor critical conditions for both failure diagnostics and failure prediction. Faced with higher asset investment costs and ever-increasing use of more sophisticated process technology, organizations are aggressively implementing these techniques and that allow detection of impending failure or degradation of performance.

Total Productive Maintenance Training & Consulting Services Page 2 In order for TPM to work successfully, there must be synergy of the five major elements defined and properly adapted to the three phases of life span. The driving force behind this success is people. TPM is a slow culture change to get people to do the right things at the right time. This culture change compliments societies’ changing attitudes, values, and priorities. TPM is a long term and worthy process…not a three worded jargon and a trendy program!!!!

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http://www.industry.net/discussions/tpm.htm [5/15/2004 10:17:34 AM] TPM - I bet an operator can do this! IDCON, INC article, Torbjorn Idhammar, Michaela Lippig

You are here > Articles > TPM – I bet an operator can do this!

TPM – I bet an operator can do this!

Maintenance The industry is well aware of the impact of preventive maintenance. Management With downward cost and price pressure and aging equipment, many Articles plants can barely keep fixing what breaks let alone perform simple equipment inspections with overtime-maxed maintenance people. Reliability The solution is clear. Break the vicious circle of reactive Discussion Torbjörn Idhammar VP and maintenance. Forum Partner,IDCON, Inc., a maintenance management Christers An obvious resource is to use early detection of problems by an consulting and training operator. Who can better detect subtle equipment changes? Think Krönika company. (articles in about your automobile. Except scheduled maintenance, the automobile operator initiates 98% of shop visits. Most automobile Swedish) operators also understand that finding problems early equals major Submit an savings. article When recommending the concept of operator inspections, a wall of objections and obstacles arises. Unions may claim this will eliminate work for their maintenance members although operators will be doing nothing more than inspections and what many union agreements already allow.

Another common objection from maintenance people, management personnel, and operators is that operators do not know how to do this. The tasks operators should perform are simple, common-sense checks. Many operators can do such inspection without training. The fact that many operators maintain their vehicles and home means Michael Lippig they are clearly capable of learning and performing complex is Business Development maintenance tasks. Manager of IDCON INC.,

Further information is available by contacting [email protected]

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Fig. 1

For example, ask an operator to inspect the AC motors in his area according to pre-set frequency and order as Fig. 1 shows. If the temperature is high near the front, a bearing problem probably exists. If the temperature is high in the middle, the difficulty is undoubtedly a winding problem or overload. If the temperature is high at the back, airflow or bearing problems may exist. I bet an operator can do this!

Many operators are already recording operating parameters such as temperature and pressure. Typically, they file these. Perhaps, a supervisor may examine them another day. This is often mere “busy work.” Teaching the “recorder” to interpret what he sees and then initiate action will provide many valuable front line observers, save uptime, and direct maintenance to the “hotspots” before they turn catastrophic. Marking gauges with the normal operating range and using graphical, eighth-grade level instructions showing the “recorder” why, what, and how to inspect makes the job of an operator more interesting and truly empower him to impact plant performance. I bet an operator can do this!

Most plants have couplings of the “tire” type, see Fig. 2 A simple inspection of a “tire” coupling is to visually inspect it for lose bolts, tears in the tire material, and worn keyways. I bet an operator can do this!

Managers need to decide if operator inspections are the proper action. If so, do not allow attitudes and objections to stand in the way. Forge ahead, make the plans, use pictorial training and reference material, train the http://www.idcon.com/articles/TPMOperatorCan.htm (2 of 3) [5/15/2004 10:17:49 AM] TPM - I bet an operator can do this! IDCON, INC article, Torbjorn Idhammar, Michaela Lippig

operators, and institute the procedures. Examples of training material for operators are available at http://www.idcon.com/bookstore/cms1.htm This will definitely be a win-win situation for the operators, maintenance personnel, and the plant. I bet you can do this!

Michael Lippig & Tor idhammar IDCON, INC.

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The Paradigm Todo Puede Movement TOTAL PRODUCTIVE Mejorarse MAINTENANCE Please click to select an option: Seleccione una opción:

TPM in America TPM en América

Definition of Maintenance Definición de Mantenimiento

History of Maintenance Historia del Mantenimiento

Challenges Retos

TPM Procedure TPM Procedimiento

What TPM is and is not Qué es TPM y qué no es

Setting priorities Definiendo prioridades

Team Roles & Responsibilities Tareas y Responsibilidades del equipo

The 5 S's Process El Proceso de las 5 S's

Autonomuos Maintenance Mantenimiento Autónomo

Technical Advantages Ventajas Técnicas

Personnel Attitude Improvement Mejoramiento de Actitudes del Personal

High Level Management's Support Apoyo de Alta Gerencia

Implement TPM, ¡Implemente TPM YA! It is Easier Than You Thought! Más Fácil de lo que Creía

Any suggestions? ¿Algunas sugerencias?

What is TPM? (handout) ¿Qué es TPM? (folleto para dar)

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Dr. Roberts' Study Estudio del Dr. Roberts

Visual Systems, High Value Resource Sistemas Visuales, Recurso de Alto Valor

in America Luego de su exitosa implementación en miles de After successful implementation in thousands importantes empresas en Asia, hacia finales de of important companies in Asia, in the later los 70's el TPM comenzó a aplicarse en América. 70's TPM started being applied in America. Importantes organizaciones como Dupont, Kodak, Motorola, Ford Motor Co., Boeing y Important organizations like Dupont, Kodak, también el Servicio Postal de los EE.UU. Motorola, Ford Motor Company, Boeing and comenzaron a usar ésta, considerada por el also the U.S.Postal Service, started using this gobierno Estadunidense como una de las "best manufacturing practice" as it has been "mejores prácticas de manufactura". Ahora called by the US Government. Now there are varios cientos de empresas ya se encuentran several hundreds of companies under TPM. bajo este innovador proceso del TPM. Sin Although, only a small percentage of embargo, sólo un pequeño porcentaje de ellas companies succeed at implementing this tienen éxito en esta disciplina. TPMonLine.com discipline. TPMonLine.com has created this ha creado este sitio para proveer de información website to supply some information and y apoyo a todos aquellos que se quieran support to those who want to take advantage beneficiar de la implementación de este sistema of implementing the maintenance system of de mantenimiento del futuro, hoy. Damos the future today. We also welcome those in the también la bienvenida a quienes al estar en implementation process who may want to proceso de implementación quieran compartir share their experiences. This is a way to sus experiencias. Esta es una buena forma de participate in the preservation of the participar en la tradicional buena voluntad y traditional good will and cooperation among cooperación entre los miembros de la members of the Manufacturing and Plant comunidad mundial de Ingeniería de Engineering community around the world that

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generates true leadership. Manufactura y de la Planta generando verdadero liderazgo. Total Productive Maintenance is one of the most valuable strategies to follow for those Mantenimiento Productivo Total, (TPM por sus who want to be competitive over the coming siglas en inglés), es una de las más valiosas "world class competition" decades. estrategias a seguir por quienes quieren estar competitivos durante las décadas de la "competencia de clase mundial".

What is the Next Machine ¿Cuál es la Siguiente Máquina We Want to Implement TPM a Implementar?

Cuando vamos a seleccionar una máquina para on? el siguiente esfuerzo de implementación de TPM, lo mejor será pensar en las más críticas. No es la When we are selecting a piece of equipment máquina que esté en el peor estado. Tampoco for the implementation of the TPM effort, we aquella que con mayor facilidad podemos dejar should be thinking of the most critical ones. It fuera de producción. Quizás será la que nos es is not the machine in the worst shape. It is not más necesaria, la que tiene la mayor carga de the machine we can give up without much trabajo. trouble. It may be the most demanded and work loaded one. TPM, dijimos, no es un proceso de reconstrucción de máquinas. Otro mito es el TPM, as we said, is not a refurbishing process. pensar que habrá una gran pérdida de tiempo It is not an overhaul program either. Another productivo. Se trata de traer la máquina a un myth would be to think of a long downtime. nivel que genere su mayor productividad, y la TPM is about bringing the machine up to a más fácil operabilidad y mantenibilidad. level where it will give us the highest La primera meta de TPM es definir las http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/tpmprocess/default.htm (3 of 7) [5/15/2004 10:18:03 AM] ! TPM and other new approaches to an effective maintenance !

productivity and the easiest operability and discrepancias y oprtunidades de mejoramiento maintainability. no solo en la máquina sino también en el área que la rodea. The first goal of a TPM team is to define what the most important discrepancies or En muchos casos, una máquina a la que se le ha improvement opportunities are, not only in the hecho TPM estará en mejores condiciones que si machine, but in the surrounding or related fuera nueva, porque probablemente habrá sido areas as well. acondicionada para servir mejor a nuestras muy particulares necesidades. Esto no tiene que ser realizado únicamente en el esfuerzo inicial, sino In many cases a TPM'd machine will be in posiblemente en las semanas (a veces son better shape than a new one because it will meses) siguientes después de la probably be easier and safer to operate under implementación. Es incluso posible que los our very particular needs. This will be miembros del equipo, en ese tiempo que siguió a accomplished not just in the initial scheduled la implementación, hayan descubierto e effort, but in the weeks (some times a few identificado nuevas oportunidades y desde luego months) to come after the implementation was decided. Maybe during those weeks the team las agregan a su programa. will be able to discover and tag more discrepancies and they will of course be En algunos casos el esfuerzo TPM no necesitará added to the schedule. detener la operación por más de uno o dos días a la semana, otros casos se pueden programar para segundo o tercer turno. Eso se debe In some cases the TPM effort will not stop the determinar por las necesidades de producción, operation for more than one or two days per pues TPM consiste en escuchar a cada miembro week, some other cases may be scheduled for de la organización y entender sus necesidades y a second or third shift. That will be determined preocupaciones. En equipos menores, unas by the production needs, because TPM is also horas serán suficientes. En realidad, escuchar a about listening to each member of the la gente de producción y organizarse de organization and understanding their conformidad es una prioridad del trabajo del concerns and needs. For minor equipment, coordinador. only a few hours may be enough.

Actually, listening to production people and organizing in accordance is the first priority of the coordinator's job.

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Technical Advantages Ventajas Técnicas

The equipment undergoing TPM will be El equipo sometido a TPM será elevado a su brought up to its optimal performance, desempeño óptimo, corrigiendo cualquier correcting any discrepancies that may be discrepancia o anomalía encontrada. También found. It will also be customized with será adaptado con modificaciones modifications mostly suggested by the principalmente sugeridas por el operador y operators and supervisors, and analyzed and supervisores de producción, analizadas y approved by the whole team. As we previously aprobadas por el equipo de trabajo en conjunto. stated, such modifications or improvements Como dijimos antes, esas modificaciones y will cover not only the machine itself, but its mejoramientos no solo cubren la máquina surrounding areas as well. misma, sino el área alrededor suyo.

Old or obsolete filtering devices being Filtros o radiadores anticuados son replaced for newly designed ones is just one reemplazados por unos de diseño avanzado, y of many examples of possible modifications como ese ejemplo muchos cambios que nos that may lead to a superior environmental llevan a una condición ambiental superior. condition. Una máquina más limpia y mejor conservada tiene menor probabilidad de sufrir una falla, A cleaner and better up-kept piece of cualquier anomalía que pudo derivar en un equipment is less likely to break down, any problema mayor, será detectada y resuelta en discrepancy that could've ended up as a major sus etapas iniciales. En términos de costo problem, will be detected and solved in the monetario, el resultado de un mejor earliest stages. In terms of dollars, the result mantenimiento se traduce en utilidades. of a better maintenance philosophy has a logical translation into profit.

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Personnel Attitude Mejoría en la Actitud del Improvement Personal

By actively participating in the improvement Mediante su participación en el mejoramiento y and upgrading of the machine, the operators, la puesta en óptimas condiciones de la máquina, supervisors and the whole team, develop a operadores, supervisores y todo el equipo de feeling of ownership. This is probably the trabajo desarrollan un sentimiento de propiedad. most important part of the TPM process. Esta es tal vez una de las partes más Participating in this kind of programs creates importantes del proceso TPM. Participando en in the individual a sentiment of pride and esta clase de proyectos se crea en cada commitment that will make them all feel a part individuo un sentido de orgullo y compromiso of the World-Class company that we are les hace sentirse parte de la empresa de Clase building together. Mundial que juntos estamos construyendo.

Very important as well, is the fact that, during También es muy importante el hecho de que, the training, the team members learn that TPM durante el entrenamiento los participantes is something that can be applied as well, in descubren que este mejoramiento es aplicable any other activity that we are performing. en cualquier otra actividad en nuestra vida. El Continuous improvement seems to be the mejoramiento contínuo parece ser la regla de oro golden rule for the future generations. It will para las generaciones futuras. Deberá have to become a part of the culture in order convertirse en una parte de la cultura para poder to survive. We all should be willing to be sobrevivir. Todos debiéramos estar deseando taught of ways to improve our over all aprender nuevas formas de mejorar nuestro desempeño en general. Es realmente una performance. It really is a Win-Win situation. situación donde todos ganamos.

High Levels of El Apoyo de los Altos Niveles Administration's Support Gerenciales

A very important factor to the success of this Un factor importante de éxito en este proyecto es project is the strong support that it has to el gran apoyo que debe recibir de los ejecutivos receive from the top executives, since it de más alto rango en la organización, ya que se requires to modify some of the old ways of requiere modificar las viejas formas de hacer las doing business and also, some times, will cosas y también se necesita el suministro de http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/tpmprocess/default.htm (6 of 7) [5/15/2004 10:18:03 AM] ! TPM and other new approaches to an effective maintenance !

require the allocation of extra resources. nuevos recursos.

To succeed, we have to get strong support Para tener buen resultado tenemos que recibir from the president or owner on down. apoyo desde el presidente o dueño de la empresa en adelante. All executives, supervisors, foremen and employees at the maintenance and all other Todos los ejecutivos, supervisores, sobrestantes departments are also expected to be willing to del departamento de mantenimiento y de todas support this effort. Many of them should have las demás áreas deben también apoyar el participated in TPM training courses before we esfuerzo. Es deseable que algunos de ellos can expect them to become advocates of this participen con anticipación en un entrenamiento formal a fin de que sean auténticos defensores philosophy. de la nueva filosofía.

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Newsletter and mailing list: Feedback To receive special TPM Tips offers and valuable information from TPM Toolkit TOTAL PRODUCTIVE MAINTENANCE CASE STUDY Marshall Institute, input Free Stuff your email address Winter/Spring MRC Bearings' TPM Journey: From Totally Painted here:

Calendar Machines to Taking Pride in Our Machines Summer/Fall In 1996 MRC Bearings, a unionized aerospace industry supplier, (We mail to our list only when we have a Calendar recognized it had a problem. They were behind on their orders. new special offer. Request Proposal Their customers were pushing for shorter lead times and cost Your email address Affiliate Links reductions. will be kept private and will not be Maintenance Approximately eighty percent of their maintenance hours were provided to other Effectiveness Audit dedicated to emergency work orders. In October of 1997 over one companies.) thousand, six hundred and sixty hours were consumed by unplanned

maintenance in just one area. Ten months later that number fell to less than thirty hours. That's over a 99% decrease.

In another area they were able to achieve almost a 98% decrease in Marshall Institute the number of unplanned maintenance hours in an eight-month and Technology Transfer Service period. Greg Folts, Manager of Continuous Improvement at MRC Strategic Alliance attributes their remarkable success to having a hardworking, Marshall Institute is dedicated maintenance team and implementing a Total Productive proud to announce Maintenance (TPM) program. a strategic alliance with Technology "We Transfer Services started to provide a total slow, maintenance beginning solution to our clients. TTS is an with a industrial training small area and consulting that was company providing critical to needs assessment, our analysis, and stand- process up instruction. With TTS providing but was technical training experiencing design and delivery chronic and Marshall problems," Institute providing http://www.marshallinstitute.com/pubs2/tpmcase.asp (1 of 5) [5/15/2004 10:18:36 AM] Marshall Institute;Maintenance Training:TPM,Total Productive Maintenance,...s, Electrical Seminars, Preventive Maintenance and Predictive Maintenance

maintenance said Folts. "At first, a lot of people were skeptical and not really systems consulting interested in getting involved with TPM," he said. "We had a core and in-house of people who were excited about TPM and we enlisted the help of seminars, we can people outside of our organization to work with us," Folts said. now provide service to any MRC worked with Preston Ingalls, President of Marshall Institute, aspect of the to organize their TPM efforts. He continued, "Preston helped us get maintenance started, but he was also our best cheerleader. He got our folks fired industry. up about TPM." One of MRC's customers, Pratt-Whitney, also supported their efforts by facilitating MRC's first TPM event and sharing their TPM practices with MRC..

MRC began with a week-long TPM event. Folts explained they would begin by cleaning, inspecting, lubricating, and performing corrective work on a piece of machinery. Once a machine was cleaned, it would be painted. At first, people were reluctant to participate in TPM events. As time went on, people began to notice what improvements were being accomplished under the TPM events. "In fact, the same people that were hesitating in the beginning were suddenly asking when their machine would be scheduled for a TPM event," Folts said.

Another individual, who one told me to keep my TPM away from his machines, now is a fully trained TPM Coordinator in his area. It's these types of things that truly amaze me. The culture change is slow, but it's happening."

MRC formed Equipment Improvement Teams (EITs) to work on resolving equipment- related issues. Folts credits the EITs with a success that was critical in their adoption of TPM. He explained they had a http://www.marshallinstitute.com/pubs2/tpmcase.asp (2 of 5) [5/15/2004 10:18:36 AM] Marshall Institute;Maintenance Training:TPM,Total Productive Maintenance,...s, Electrical Seminars, Preventive Maintenance and Predictive Maintenance piece of equipment with chronic problems. It was breaking down monthly requiring three or four days each time to fix. He explains, "We were really frustrated by this problem, we kept fixing it only to see it break down again."

manufacturing excellence."

MRC trained ten TPM Area Coordinators who are dedicated to TPM one week each month. These TPM Coordinators organize TPM events in their areas, also lead EITs, and make sure the process keeps working. MRC has begun to create full-time TPM teams. One such team, comprised of Jeff Franklin, an Electrician and Jim Klugh, a Mechanic, and Jeff Johnson, an Operator, were able to correct a long-standing equipment problem which reduced the scrap produced by that equipment to almost zero.

Folts and Russell attribute their success in implementing TPM to seven things. Russell said, "We realized early on that we couldn't do it all. So we identified a few areas that we felt were key, we did those things, and we did them well." The areas that MRC focused on were:

Preventative maintenance

From this experience, Russell suggests organizations beginning TPM programs start small and keep it simple.

Did MRC learn any lessons implementing TPM? Folts said, "We learned that training is a key to being successful with TPM. We did some initial TPM awareness training for the organization, about one week of training with the operators, and some for the mechanics. But, looking back we could have had quicker success if we had done more training." Folts also credits their success to the support of their management, the U.A.W. union, the hard work of the people at MRC, involvement of Marshall Institute, and the support of their customers. "Ultimately this is a people issue and we are lucky to have the right people involved," he said.

Thinking back about the initial resistance to TPM, Don Russell laughs and says, "At first a lot of folks here defined TPM as 'Totally Painted Machines'. Now I can say we all define TPM as 'Taking Pride in our Machines'."

http://www.marshallinstitute.com/pubs2/tpmcase.asp (4 of 5) [5/15/2004 10:18:36 AM] Marshall Institute;Maintenance Training:TPM,Total Productive Maintenance,...s, Electrical Seminars, Preventive Maintenance and Predictive Maintenance

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TPM TOTAL PRODUCTIVE TPM Mantenimiento Productivo MAINTENANCE History and Total, su Definición e Historia por el Dr. Jack Roberts Basic Implementation Process [email protected] by Jack Roberts, Ph.D. [email protected] Departmento de Tecnología e Ingeniería Industrial Department of Industrial and Engineering Technology Texas A&M University-Commerce Texas A&M University-Commerce Sinopsis: Mantenimiento ProductivoTotal, Abstract: Total Productive Maintenance (TPM por sus siglas en inglés), es un (TPM) is a maintenance program which concepto nuevo en cuanto al envolvimiento involves a newly defined concept for del personal productivo en el maintaining plants and equipment. The mantenimiento de plantas y equipos. La goal of the TPM program is to markedly meta del TPM es incrementar notablemente increase production while, at the same la productividad y al mismo tiempo levantar time, increasing employee morale and la moral de los trabajadores y su job satisfaction. The TPM program satisfacción por el trabajo realizado. El closely resembles the popular Total sistema del TPM nos recuerda el concepto Quality Management (TQM) program. tan popular de TQM "Manufactura de Many of the same tools such as Calidad Total" que surgió en los 70's y se ha employee empowerment, benchmarking, mentenido tan popular en el mundo documentation, etc. are used to industrial. Se emplean muchas implement and optimize TPM. This paper herramientas en común, como la delegación will define TPM in some detail, evaluate de funciones y responsabilidades cada vez its strengths and weaknesses as a más altas en los trabajadores, la maintenance philosophy, and discuss comparación competitiva, asi como la implementation procedures. Examples documentación de los procesos para su of successfully implemented programs mejoramiento y optimización. Este artículo will be presented. describe al TPM en detalle y valora sus debilidades y cualidades como filosofía de I. What is Total Productive Maintenance? mantenimiento y discute sus Total Productive Maintenance (TPM) is a procedimientos de implementación. maintenance program concept. Se presentan también algunos ejemplos de Philosophically, TPM resembles Total implementación exitosa. http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/tpmroberts.htm (1 of 11) [5/15/2004 10:19:05 AM] TPM Process - Proceso TPM

Quality Management (TQM) in several I. Qué es Total Productive Maintenance? aspects, such as (1)total commitment to (Mantenimiento Productivo Total) the program by upper level management (NT)= Nota del traductor: En el artículo se empleará la is required, (2) employees must be abreviatura TPM pues se ha convertido en un nombre empowered to initiate corrective action, que todos quienes estamos en el mantenimiento and (3) a long range outlook must be industrial entendemos. accepted as TPM may take a year or Filosóficamente, el TPM recuerda como se more to implement and is an on-going dijo antes, algunos aspectos valiosos del process. Changes in employee mind-set TQM "Manufactura de Calidad Total" o toward their job responsibilities must también Total Quality Management, take place as well. (Gerencia de Calidad Total) entre ellos: TPM brings maintenance into focus as a (1) El compromiso total por parte de los necessary and vitally important part of altos mandos de la empresa, es the business. It is no longer regarded as indispensable. a non-profit activity. Down time for (2) El personal debe tener la suficiente maintenance is scheduled as a part of delegación de autoridad para implementar the manufacturing day and, in some los cambios que se requieran. cases, as an integral part of the (3) Se debe tener un panorama a largo manufacturing process. It is no longer plazo, ya que su implementación puede simply squeezed in whenever there is a tomar desde uno hasta varios años. break in material flow. The goal is to (4) También deberá tener lugar un cambio hold emergency and en la mentalidad y actitud de toda la gente unscheduled maintenance to a involucrada en lo que respecta a sus minimum. nuevas responsabilidades. II. When and where did TPM originate? TPM le dá un nuevo enfoque al TPM evolved from TQM, which evolved mantenimiento como una parte necesaria y as a direct result of Dr. W. Edwards vital dentro del negocio. Se hace a un lado el antiguo concepto de que éste es una Deming's influence on Japanese industry. Dr. Deming began his work in actividad improductiva y se otorgan los Japan shortly after World War II. As a tiempos requeridos para mantener el equipo que ahora se consideran como una parte statistician, Dr. Deming initially began to show the Japanese how to use del proceso de manufactura. No se statistical analysis in manufacturing and considera ya una rutina a ser efectuada sólo cuando el tiempo o el flujo de material lo how to use the resulting data to control quality during manufacturing. The initial permitan. La meta es reducir los paros de emergencia, los servicios de mantenimiento statistical procedures and the resulting quality control concepts fueled by the inesperados se reducirán a un mínimo. -- En un taller de tubería de acero, por ejemplo, http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/tpmroberts.htm (2 of 11) [5/15/2004 10:19:05 AM] TPM Process - Proceso TPM Japanese work ethic soon became a way las máquinas dobladoras que entre of life for Japanese industry. This new reajustes para cambio de medidas y manufacturing concept eventually reparaciones llegaban a perder hasta más became knows as Total Quality del 30% de su productividad, hoy los Management or TQM. tiempos perdidos son menores al 3%(NT).

When the problems of plant II. ¿Cuándo y Dónde se originó el TPM? maintenance were examined as a part of En realidad el TPM es una evolución de la the TQM program, some of the general Manufactura de Calidad Total, derivada de concepts did not seem to fit or work well los conceptos de calidad con que el Dr. W. in the maintenance environment. Edwards Deming's influyó tan Preventative maintenance (PM) positivamente en la industria Japonesa. El procedures had been in place for some Dr. Deming inició sus trabajos en Japón a time and PM was practiced in most poco de terminar la 2a. Guerra Mundial. plants. Using PM techniques, Como experto en estadística, Deming maintenance schedules designed to comenzó por mostrar a los Japoneses cómo keep machines operational were podían controlar la calidad de sus developed. However, this technique productos durante la manufactura mediante often resulted in machines being over- análisis estadísticos. Al combinarse los serviced in an attempt to improve procesos estadísticos y sus resultados production. The thought was often "if a directos en la calidad con la ética de trabajo little oil is good, a lot should be better." propia del pueblo japonés, se creó toda una Manufacturer's maintenance schedules cultura de la calidad, una nueva forma de had to be followed to the letter with little vivir. De ahí surgió TQM, "Total Quality thought as to the realistic requirements Management" un nuevo estilo de manejar la of the machine. There was little or no industria. involvement of the machine operator in En los años recientes se le ha denominado the maintenance program and más comunmente como "Total Quality maintenance personnel had little Manufacturing" o sea Manufactura de training beyond what was contained in Calidad Total. Cuando la problemática del often inadequate maintenance manuals. mantenimiento fué analizada como una parte del programa de TQM, algunos de sus The need to go further than just conceptos generales no parecían encajar en scheduling maintenance in accordance el proceso. Para entonces, ya algunos with manufacturer's recommendations procedimientos de Mantenimiento as a method of improving productivity Preventivo (PM) -ahora ya prácticamente and product quality was quickly obsoleto(NT)- se estaban aplicando en un recognized by those companies who gran número de plantas. were committed to the TQM programs. To solve this problem and still adhere to Usando las técnicas de PM, se

http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/tpmroberts.htm (3 of 11) [5/15/2004 10:19:05 AM] TPM Process - Proceso TPM the TQM concepts, modifications were desarrollaron horarios especiales para made to the original TQM concepts. mantener el equipo en operación. Sin These modifications elevated embargo, esta forma de mantenimiento maintenance to the status of being an resultó costosa y a menudo se daba a los integral part of the overall quality equipos un mantenimiento excesivo en el program. intento de mejorar la producción. Se aplicaba la idea errónea de que "si un poco The origin of the term "Total Productive de aceite es bueno, más aceite debe ser Maintenance" is disputed. Some say that mejor". Se obedecía más al calendario de it was first coined by American PM que a las necesidades reales del equipo manufacturers over forty years ago. y no existía o era mínimo el envolvimiento Others contribute its origin to a de los operadores de producción. Con maintenance program used in the late frecuencia el entrenamiento de quienes lo 1960's by Nippondenso, a Japanese hacían se limitaba a la información (a veces manufacturer of automotive electrical incompleta y otras equivocada), contenida parts. Seiichi en los manuales. Nakajima, an officer with the Institute of Plant Maintenance in Japan is credited La necesidad de ir más allá que sólo with defining the concepts of TPM and programar el mantenimiento de seeing it implemented in hundreds of conformidad a las instrucciones o plants in Japan. recomendaciones del fabricante como método de mejoramiento de la Books and articles on TPM by Mr. productividad y la calidaddel producto, se Nakajima and other Japanese as well as puso pronto de manifiesto, especialmente American authors began appearing in entre aquellas empresas que estaban the late 1980's. The first widely attended comprometiéndose en los programas de TPM conference held in the United Calidad Total. Para resolver esta States occurred in 1990. Today, several discrepancia y aún mantener congruencia consulting companies routinely offer con los conceptos de TQM, se le hicieron TPM conferences as well as provide ciertas modificaciones a esta disciplina. consulting and coordination services for Estas modificaciones elevaron el companies wishing to start a TPM mantenimiento al estatus actual en que es program in their plants. considerado como una parte integral del programa de Calidad Total. III. Implementation of TPM El origen del término "Mantenimiento To begin applying TPM concepts to Productivo Total" (TPM) se ha discutido en plant maintenance activities, the entire diversos escenarios. Mientras algunos work force must first be convinced that afirman que fué iniciado por los upper level management is committed to manufactureros americanos hace más de the program. The first step in this effort http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/tpmroberts.htm (4 of 11) [5/15/2004 10:19:05 AM] TPM Process - Proceso TPM is to either hire or appoint a TPM cuarenta años, otros lo asocian al plan que coordinator. It is the responsibility of the se usaba en la planta Nippodenso, una coordinator to sell the TPM concepts to manufacturera de partes electricas the work force through an educational automotrices de Japón a fines de los 1960's. program. To do a thorough job of Seiichi Nakajima un alto funcionario del educating and convincing the work force Instituto Japonés de Mantenimiento de la that TPM is just not another "program of Planta, (JIPM), recibe el crédito de haber the month," will take time, perhaps a definido los conceptos de TPM y de ver por year or more. su implementación en cientos de plantas en Japón. Once the coordinator is convinced that the work force is sold on the TPM Los libros y artículos de Nakajima así como program and that they understand it and otros autores japoneses y americanos its implications, the first study and comenzaron a aparecer a fines de los action teams are formed. These teams 1980's. En 1990 se llevó a cabo la primera are usually made up of people who conferencia en la materia en los EEUU. Hoy directly have an impact on the problem día, varias empresas de consultoría están being addressed. Operators, ofreciendo servicios para asesorar y maintenance personnel, shift coordinar los esfuerzos de empresas que supervisors, schedulers, and upper desean iniciar sus plantas en el promisorio management might all be included on a sistema de TPM. team. Each person becomes a "stakeholder" in the process and is III. Implementación del TPM encouraged to do his or her best to contribute to the success of the team Para iniciar la aplicación de los conceptos effort. Usually, the TPM coordinator de TPM en actividades de mantenimiento de heads the teams until others become una planta, es necesario que los familiar with the process and natural trabajadores se enteren de que la gerencia team leaders emerge. del más alto nivel tiene un serio compromiso con el programa. El primer The action teams are charged with the paso en este esfuerzo es designar o responsibility of pinpointing problem contratar un coordinador de TPM de tiempo areas, detailing a course of corrective completo. Será la labor de ese coordinador action, and initiating the corrective el "vender" los conceptos y bondades del process. Recognizing problems and TPM a la fuerza laboral a base de un initiating solutions may not come easily programa educacional. Se debe convencer for some team members. They will not al personal de que no se trata simplemente have had experiences in other plants del nuevo "programa del mes", where they had opportunities to see how simplemente esa culturización puede tomar things could be done differently. In well hasta más de un año.

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run TPM programs, team members often Una vez que el coordinador está seguro de visit cooperating plants to observe and que toda la fuerza laboral ha "comprado" el compare TPM methods, techniques, and programa de TPM y que entienden su to observe work in progress. This filosofía e implicaciones, se forman los comparative process is part of an overall primeros equipos de acción. measurement technique called "benchmarking" Los equipos de acción tienen la and is one of the greatest assets of the responsabilidad de determinar las TPM program. discrepancias u oportunidades de mejoramiento, la forma más adecuada de The teams are encouraged to start on corregirlas o implementarlas e iniciar el small problems and keep meticulous proceso de corrección o de mejoramiento. records of their progress. Posiblemente no resulte fácil para todos los Successful completion of the team's miembros del equipo el reconocer las initial work is always recognized by oportunidades e iniciar las acciones, sin management. Publicity of the program embargo otros tal vez tengan experiencia de and its results are one of the secrets of otras plantas o casos previos en la misma y making the program a success. Once gracias a lo que hayan observado en el the teams are familiar with the TPM pasado y las comparaciones que puedan process and have experienced success establecer, se logrará un importante with a small problem, problems of ever avance. El establecimiento de estas increasing importance and complexity comparaciones que a veces pueden are addressed. implicar visitar otras plantas, se denomina "benchmarking" o sea "comparación sobre As an example, in one manufacturing la mesa" como cuando tenemos dos plant, one punch press was selected as aparatos de las mismas características y los a problem area. The machine was ponemos sobre la mesa para comparar studied and evaluated in extreme detail cada parte en su proceso de by the team. Production over an funcionamiento. Esta es una de las grandes extended period of time was used to ventajas del TPM. establish a record of productive time versus nonproductive time. Some team A los equipos se les anima a iniciar members visited a plant several states atacando discrepancias y mejoras menores away which had a similar press but y a llevar un registro de sus avances. A which was operating much more medida que alcanzan logros, se les dá efficiently. This visit gave them ideas on reconocimiento de parte de la gerencia. A how their situation could be improved. A fin de que crezca la confianza y el prestigio course of action to bring the machine del proceso, se la dá la mayor publicidad into a "world class" manufacturing que sea posible a sus alcances. A medida condition was soon designed and work que la gente se va familiarizando con TPM, http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/tpmroberts.htm (6 of 11) [5/15/2004 10:19:05 AM] TPM Process - Proceso TPM was initiated. The work involved taking los retos se van haciendo mayores ya que the machine out of service for cleaning, se emprenden proyectos de más painting, adjustment, and replacement importancia. of worn parts, belts, hoses, etc. As a part of this process, training in Como ejemplo, en una planta manufacturera operation and maintenance of the una prensa sacabocados fué seleccionada machine was reviewed. A daily check list como área de problema, la máquina fué of maintenance duties to be performed estudiada muy detalladamente por el equipo by the operator was developed. A TPM. Se hicieron observaciones de tiempo factory representative was called in to productivo y de paros por fallas o por assist in some phases of the process. cambios de herramienta (tiempo improductivo), algunos miembros del After success has been demonstrated equipo tuvieron la oportunidad de visitar on one machine and records began to otra planta que tenía una máquina igual show how much the process had pero usándola con mayor eficiencia. Esta improved production, another machine visita les dió varias ideas de mejoramiento was selected, then another, until the para traer la máquina a una operación entire production area had been brought competitiva tipo "clase mundial" y se trazó into a "world class" condition and is un plan de acción. Se procedió a seguir el producing at a significantly higher rate. plan, se hizo limpieza, cambio de partes desgastadas, bandas, mangueras, pintura y Note that in the example above, the ajustes necesarios. Como parte del operator was required to take an active proceso, se revisaron los procedimientos part in the maintenance of the machine. de operación y mantenimiento y se dió la This is one of the basic innovations of capacitación necesaria. Un representante TPM. The attitude of "I just operate it!" is de la fábrica de la máquina fué llevado para no longer acceptable. Routine daily apoyar en algunas partes de este proceso. maintenance checks, minor adjustments, lubrication, and minor part El éxito quedó demostrado, los registros de change out become the responsibility of tiempo productivo de la máquina the operator. Extensive overhauls and comenzaron a marcar un avance tanto en el major breakdowns are handled by plant proceso como en la productividad. Se maintenance personnel with the seleccionó otra máquina, luego otra y así operator assisting. Even if outside sucesivamente hasta completar la tarea de maintenance or factory experts have to convertir esa planta a "clase mundial" y be called in, the equipment operator traerla a mejores niveles de rendimiento. must play a significant part in the repair process. Nótese que en este ejemplo, el operador de la máquina tomó parte activa en el proceso. Training for TPM coordinators is Esa es una parte escencial de la innovación available from several sources. Most of que implica el TPM. Aquella actitud de "yo http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/tpmroberts.htm (7 of 11) [5/15/2004 10:19:05 AM] TPM Process - Proceso TPM

the major professional organizations nada más opero la máquina" ya no es associated with manufacturing as well aceptable. Los diarios chequeos de as private consulting and educational lubricación, detalles y ajustes menores así groups have information available on como reparaciones simples, cambios de TPM implementation. The Society of partes, etc. se convierten en parte de las Manufacturing Engineers (SME) and responsabilidades del operador. Claro que Productivity Press are two examples. reparaciones mayores o problemas Both offer tapes, books, and other técnicos siguen siendo atendidos por el educational material that tell the story of personal de mantenimiento, o técnicos TPM. Productivity Press conducts externos si es necesario, y ahora cuentan frequent seminars in most major cities con un mayor apoyo, más clara información around the United States. They also y una real participación de parte del sponsor plant tours for benchmarking operador. and training purposes. El entrenamiento para coordinadores de IV. The Results of TPM TPM se puede obtener de diversos proveedores, instituciones privadas, Ford, Eastman Kodak, Dana Corp., Allen (TPMonLine entre ellos por ejemplo), Bradley, Harley Davidson; these are just asociaciones de profesionales y además a few of the companies that have hay un buen número de publicaciones implemented TPM successfully. All especializadas. Hay varios seminarios report an increase in productivity using principalmente en los EEUU. Algunas de TPM. estas empresas de capacitación están Kodak reported that a $5 million ofreciendo recorridos por las plantas investment resulted in a $16 million exitosas, lo que sirve para tomar buenas increase in profits which could be traced ideas y ejemplos, así como establecer and directly contributed to implementing comparaciones. a TPM program. One appliance manufacturer reported the time required IV. Los Resultados de TPM for die changes on a forming press went from several hours down to twenty Ford, Eastman Kodak, Dana Corp., Allen minutes! Bradley, Harley Davidson; son solamente This is the same as having two or three unas pocas de las empresas que han additional million dollar machines implementado TPM con éxito. Todas ellas available for use on a daily basis without reportan una mayor productividad gracias a having to buy or lease them. Texas esta disciplina. Kodak por ejemplo, reporta Instruments reported increased que con 5 millones de dólares de inversión, production figures of up to 80% in some logró aumentar sus utilidades en $16 areas. Almost all the above named millones de beneficio directamente derivado companies reported 50% or greater de implementar TPM. Una fábrica de http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/tpmroberts.htm (8 of 11) [5/15/2004 10:19:05 AM] TPM Process - Proceso TPM

reduction in aparatos domésticos informa de la down time, reduced spare parts reducción en cambio de dados en sus inventory, and increased on-time troqueladoras de varias horas a sólo 20 deliveries. The need for out-sourcing minutos! Esto equivale a tener disponibles part or all of a product line was greatly el equivalente a dos o tres máquinas más, reduced in many cases. con valor de un millon de dólares cada una, pero sin haber que tenido que comprarlas o V. Conclusion rentarlas. En algunas de sus divisiones, Texas Instruments reporta hasta un 80% de Today, with competition in industry at an incrementos de su productividad. all time high, TPM may be the only thing Prácticamente todas las empresas that stands between success and total mencionadas aseguran haber reducido sus failure for some companies. It has been tiempos perdidos por fallas en el equipo en proven to be a program that works. It 50% o más, también reducción en can be adapted to work not only in inventarios de refacciones y mejoramiento industrial plants, but in construction, en la puntualidad de sus entregas. La building maintenance, transportation, necesidad de subcontratar manufactura and in a variety of other situations. también se vió drásticamente reducida en la Employees must be educated and mayoría de ellas. convinced that TPM is not just another "program of the month" and that V. Conclusión management is totally committed to the program and the extended time frame Hoy con una competitividad mayor que necessary for full implementation. If nunca antes, es indudable que el TPM es la everyone involved in a TPM program diferencia entre el éxito o el fracaso para does his or her part, an unusually high muchas empresas. Ha quedada rate of return compared to resources demostrada su eficacia no sólo en plantas invested may be expected. industriales, también en la construcción, el mantenimiento de edificios, transportes y VI. References: varias otras actividades incluidos varios deportes (NT). Los empleados de todos los 1. Productivity Press, Inc., P.O. Box niveles deben ser educados y convencidos 13390, Portland, OR 97213-0390 de que TPM no es "el programa del mes", 2. Robinson, Charles J., Ginder, Andrew sino que es un plan en el que los más altos P., "Implementing TPM", Productivity niveles gerenciales se hallan comprometidos para siempre, incluida la Press, Portland Oregon, 1995. gran inversión de tiempo mientras que dure 3. Society of Manufacturing Engineers, su implementación. Si cada quien se P.O. Box 6028, Dearborn, MI 48121 compromete como debe, los resultados serán excelentes comparados con la

http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/tpmroberts.htm (9 of 11) [5/15/2004 10:19:05 AM] TPM Process - Proceso TPM 4. Steinbacher, Herbert R., Steinbacher, inversión realizada. Norma L., "TPM for America", Traducción de Enrique Mora en Productivity Press, Portland, Oregon, exclusiva para TPMonLine 1995. Copyright 1999

5. Takahashi, Yoshikazu, and Osada, Takashi, "TPM", Asian Productivity Organization, Tokyo, 1990

The Technology Interface / Fall 1997

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For more products related to this topic visit our TPM Implementation Experiences Product Showcase

By: Siam Yoke ChoyDS

Abstract For other articles related to this topic This paper provides some information on the historical background of TPM visit our Reference introduction to Infineon Technologies followed by the chronicle events and Library. experiences learnt in adopting and adapting TPM development activities to improve productivity in DS Business Unit. It also identifies some of the difficulties faced while implementing TPM and finally proposes some solutions for eliminating them. top • Introduction

Like many organizations continue searching for excellence approaches / programs to improve their competitiveness, top management introduced Need more training? Total Productive Maintenance (TPM) in 1994 to Siemens Malacca (former Search Database of company name of Infineon Technologies). At that time, some selected training courses and people were trained on the TPM methodology however the initiative did not conferences on these achieve the expected result. Without giving up the hope, top management subjects in our made the second attempt and reinitiated the TPM program in 1996 with the following main events. Tradeshow/Seminar Search Section • TPM blast-off for management

• TPM training for implementation teams

• Establish TPM management team

• Prepare TPM implementation plan

• TPM training for supervisors & engineers

• Pilot TPM teams in Business Units

• TPM training for operators & technicians

2. TPM Development Activities in DS

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In mid of 1996,SOT23 is the highest volume runner in DS and the bottleneck process was at testing area. Unanimously, DS management has chosen SOT23 inliner as the pilot project to launch TPM initiative because it accounted for about 60% of the SOT23 capacity.

Prior to that, the DS management established an organization structure to coordinate and support the TPM efforts and activities. This is done through the formation of the DS TPM Steering Committee team and the assignment top of a full time departmental coordinator to develop the TPM master plan, control the standardization of the TPM implementation and regularly review the progress. In addition, there is a pool of TPM facilitators in DS Business Unit to implement the TPM development activities.

In the initial roll out of TPM activities, DS implemented two out of the five fundamental development activities (pillars) at that time namely Jishu Hozen Autonomous Maintenance and Kobetsu Kaizen.

Jishu Hozen Autonomous Maintenance (JHAM) – Teams of operators performance routine maintenance tasks and participate in improvement activities that halt accelerated deterioration, control contamination and maintain optimal machine conditions. It is typically implemented in eight steps in our factory

Kobetsu Kaizen (KK, Focused equipment improvement)- Cross functional project teams composed of people from production, maintenance, top engineering and operators in activities to minimize equipment losses.

At that point of time, the company was also launching a new work-floor management system called Self- Managing Team (SMT) and this had created some confusion in the early stages as well as priority / focus of both initiatives. As a result the TPM implementation has taken a longer time than it should be.

The JHAM implementation is the toughest among all the TPM development activities as it affect more people who have to change the ways they do things (culture). The JHAM journey started off with the 1 st step: initial cleaning which took about a year to pass the certification. Step by step, Self-Managing Team implemented the JHAM from step 1 to step 4 till to- date. Some of the important requisites for the successful JHAM implementation are training, step audits, activity board, meeting, One Point Lesson, and last but not least reward and recognition system. Furthermore, the assigning of office hour TPM coordinators by production have greatly helped to facilitate the JHAM implementation.

Milestone Events

1996 pilot group SOT23 inliner

1997 JHAM Step 1

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1998 JHAM step 2

1999 JHAM step 3

2000 JHAM step 4

2001 Skill level 1

…

As for the Kobetsu Kaizen, the formation of the focused equipment improvement team and ownership by production has overcome many difficulties faced in most improvement projects. A full time supervisor who has been empowered by the superior coordinated the improvement activities through data collection, equipment loss analysis, countermeasure implementation and confirmation. In the beginning, that team mainly focused on reducing equipment losses followed by expanding the scope to improve operating efficiency namely change lot time optimization. One of the good practices was that the team met regularly to discuss/review the status of the improvement activities so that every member was informed about their contributions. It is observed that the team is possible to achieve the dramatic and sustainable result due to a common shared goal and good teamwork among the members. In addition, the readily available and easily accessible equipment performance measurements namely output, uptime/downtime, overall equipment efficiency, etc through real time on line monitoring system (mTPM) has also enabled the change process.

In between, the operators and production technicians are regularly trained on equipment/process-related knowledge and skills using a unique and strategic training concept: One Point Lesson used extensively in the progress of TPM implementation. Gradually, more and more operators and production technicians follow established/standard operating procedures that has one way or the other minimized the variability in the production process.

Initially, the maintenance department personnel also participated in the TPM activities through restoring the equipment to its original and basic conditions as much as possible. The effect of the restoration if done objectively will minimize the frequent reactive maintenance practices. There after, the maintenance personnel will have more time to involve in higher value-added activities by continuous improvement of equipment reliability and maintainability.

In view of the successful result achieved through this pilot TPM, DS management unanimously decided to deploy this approach to all product groups. This is made possible through the assigning of experienced TPM practitioners from the pilot groups to facilitate the TPM implementation to all products groups in DS. The leverage of TPM best practices internally has significantly shorted the learning cure to achieve similar results in the DS

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Business Unit.

3. Results

All these TPM development activities which are synergy to each other have brought about enormous and sustainable productivity improvement in this pilot project. Before TPM, the plan module capacity of SOT23 inliner was 80'0 million per year and in most cases the actual capacity was hugging below this value. Currently, the module capacity of SOT23 inliner can reach more then 100'0 million. As a result, the bottleneck has shifted to End Of Line process. Same approach is replicated to improve the equipment capacity in others bottleneck processes within all the product groups in DS.

Summary of some of the results

Capacity of SOT23-2up > 37%

Capacity of SOT3x3-2up > 27%

Capacity of SOD323 > 30%

Capacity of SOT223 > 19% (within 3-4 months)

• Leassons Learned

Measuring TPM Effectiveness

For any improvement strategy to be successful there must be a way to measure how are we doing and how do we compare with others. TPM uses a key performance indicator call Overall Equipment Efficiency (OEE) to measure the productivity (effectiveness and efficiency) of equipment.

OEE = Availability x Uptime Utilisation x Process Performance x Quality Yield

Availability is the time the equipment is available to run (uptime)

Uptime Utilisation is the idling / engineering time

Process Performance is the actual vs. the design speed

Quality yield is the total product produced minus the rejects divided by the total product produced

All these figures are usually expressed in percentage and higher OEE

http://www.maintenanceresources.com/referencelibrary/ezine/TPMimplementation.htm (4 of 8) [5/15/2004 10:19:14 AM] Implementing a New Maintenance Management Approach translates into higher capacity from the equipment. Surprisingly, the OEE of most equipment range from 40%-60% when first time take the measurement whereas the benchmark is 85%. As such, OEE has become the accepted indicator to assess how plants actually manage their most expensive asset, the equipment to produce saleable good with minimum losses and wastes.

Implementing TPM

Although JIPM has established and simplified a 12 steps in TPM development programs (attachment 1), however most organisations implementing TPM on their own have never get off the ground the first time and for those who manage to kick start do not achieve the expected and sustainable productivity improvement.

Introducing and implementing TPM is not like a standard project, which normally has a starting, and an end that seldom exceeds one year. Rather, TPM is a long range “ living program ” which can take more than few years to implement and enjoy the lasting benefits when the whole organisation has become strategy focused instead of evaluating one new program after another before implementing TPM thoroughly.

Why is TPM difficult to implement?

In actual fact, implementing TPM is a dramatic organisational change that can affect organisation structure, work-floor management system, employee responsibilities, performance measurement, incentive systems, skill development and the use of information technology. No wonder the success rate of such large-scale change is less than 30% for most organisations.

Difficulties faced in TPM implementation

• Typically people show strong resistance to change.

• Many people treat it just another “ program of the month ” without paying any focus and also doubt about the effectiveness.

• Not sufficient resources ( people,money,time,etc.) and assistance provided

• Insufficient understanding of the methodology and philosophy by middle management

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• TPM is not a “ quick fix ” approach, it involve cultural change to the ways we do things

• Departmental barrier existing within Business Unit

• Many people considered TPM activities as additional work/threat

5. Conclusion & Recommendations

TPM is one of the world class lean manufacturing strategies that is well structured with eight fundamental development activities and data based approach (OEE) to improve both the effectiveness and efficiency of any production system/process involving everyone.

Apparently, successful TPM implementation can achieve better and lasting result as compared to other isolated program because there is an ultimate change in people (knowledge, skills, and behaviour) during the progress. However don't underestimate the tremendous efforts required to make that change happened and last.

If we have to start over again…some serious thoughts

Top management (strong & consistent involvement/commitment)

• Create a communication campaign & frequently reinforce the need to change

• Establish the organisation e.g. steering team/TPM co-ordinator/TPM office

• Create a TPM deployment through sponsor,owner,users and coach

• Provide the needed means and resources (equipment, space, training, money, etc.)

• Engage a knowledgeable consultant

• Establish reward and recognition system

• Review the implementation status regularly

Middle management (strong understanding TPM methodology &

http://www.maintenanceresources.com/referencelibrary/ezine/TPMimplementation.htm (6 of 8) [5/15/2004 10:19:14 AM] Implementing a New Maintenance Management Approach philosophy)

• Ownership of TPM implementation ( KK & JHAM )

• Active promotion and sustenance (training, coaching, etc.) to the direct staff

• Visit the line frequently to show your interest

• Provide supporting environment by removing barriers

• Promote TPM activities through activity boards and best practices sharing

Direct staff (active participation in TPM activities)

• Learn autonomous maintenance by doing

• Suggest new ideas for improvement

• Raise equipment/process-related knowledge and skills

• Participate in equipment and process improvement activities

Teamwork between production,maintenance,and engineering

• Use of cross functional teams is important for TPM success

Information Technology

- Use information technology to gather equipment information

6. Attachments

Attachment 1: JIPM 12 steps development program

7. Acknowledgements

The author wishes to thank all TPM teams, TPM Facilitators, and SMT members in DS for their cooperation and contributions to make TPM successful

8. References

• S. Nakajima [1989] “ TPM Development Program ”, Productivity Press

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• K. Shirose [1996]“ TPM New Implementation Program in Fabrication & Assembly Industries ”, JIPM

• JIPM, Japan Institute of Plant Maintenance

[email protected]

http://www.maintenanceresources.com/referencelibrary/ezine/TPMimplementation.htm (8 of 8) [5/15/2004 10:19:14 AM] TPM Agent of Destruction!

In a recent classroom presentation, one of the most demanding participants came to ¡El TPM Agente de the front and talking to the group he said: "I Destrucción! am going to show here, how TPM can become an agent of destruction". Very En una reciente presentación, uno de los serious he drafted a circle on the board and participantes más exigentes vino al frente de la traced three sectors, naming each as we see clase y dirigiéndose al grupo dijo: "Voy a in the image. Then he said: "For years these mostrarles aquí, cómo el TPM puede convertirse three groups have been discussing who is to en un agente de destrucción". Muy serio, trazó un blame for everything that happens"... "Now, círculo en el tablero y lo dividió en tres sectores just after this initial implementation nombrándolos como vemos en el dibujo. exercises, we find that these protective Entonces dijo: "Por años estos tres grupos barriers are getting demolished"... "No hemos estado discutiendo quién tiene la culpa longer is it my problem or your problem, but cada vez que algo sucede"... "Ahora, solamente OUR problem. No longer is it your con estos ejercicios iniciales de implementación, accomplishment or mine but OURS" descubrimos que estas barreras protectoras se están destruyendo"... "Ya no es tu problema o mi problema, sino NUESTRO problema. No más es tu logro o el mío, sino el NUESTRO"

En efecto, esta percepción es verdadera, podemos ver cómo en estos grupos de trabajo de TPM, la gente junta sus cualidades y diluye sus deficiencias en un ambiente amistoso. Los supervisores y gerentes de todos los niveles ganan mucho respeto y reconocimiento de su gente. Mientras más se acercan a los problemas y necesidades mejor es su comprensión. Este ambiente de liderazgo no es común en ninguna otra disciplina o actividad. Yo puedo afirmar que no sólo las barreras departamentales se rompen para bien de todos, pero también los niveles jerárquicos se funden de manera que mejorará sus comunicaciones y superará sus funciones. Una gran gama de beneficios se hacen presentes cuando vemos las relaciones humanas como el eje de cualquier actividad. La manufactura requiere esa clase de mejoras para enfrentar los nuevos retos. El conocimiento y sabiduría de los niveles más bajos de la organización son un recurso valioso que tradicionalmente se ha desperdiciado. No más, las nuevas disciplinas y filosofías nos están permitiendo despertar al hecho de que ningún recurso debe pasar desapercibido. Podemos y debemos hacer uso de las buenas comunicaciones y el adecuado "don de gentes" para desarrollar esa riqueza.

http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/destruction.htm (1 of 2) [5/15/2004 10:19:22 AM] TPM Agent of Destruction!

Enrique Mora

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Uptime at Minimum Cost in the Process Industries

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Author : Bill Hughes Group TPM Manager SAPPI Forest Products, South Africa

INTRODUCTION For any connoisseur of maintenance, the publication of Reliability Centered Maintenance (RCM) in 1978 heralded a new dawn. Not only did it provide an answer to the “ Hard Time Paradox” but it also provided the Engineer with logical tools to determine “What should be maintained”, “Why it should be maintained” and “How it should be maintained”. Coupled to the release of the Air Transport Association maintenance planning document (MSG-3) in October 1980 with its improved rigor for maintenance task identification, treatment of hidden function failures and improved focus on lubrication and servicing, the scene was set for Preventive Maintenance to come of age.

Twenty years later as we march into the new millenium, it is apparent that relatively few companies have been successful in implementing this reliability approach to preventive maintenance programs, or for that matter recognizing that an in-depth understanding of the failure process of significant production equipment, is a pre- requisite for any manufacturing company to attain and sustain World class standards.

This paper attempts to share some of the key learning points, realized over a period of twenty years in the Brewing/Paper and Pulp industry with implementation experience at nineteen plants on a wide range of continuous process equipment.

OPERATING CONTEXT DIFFERENCES Many articles have been written about RCM and the need to rigidly follow the analytical approach developed by Nowlan and Heap of Eastern Airlines for new aircraft . Proponents of this rigid approach ignore the significant differences that exist between the various industries

Commercial Airlines The realization in the Airlines that many types of failures could not be prevented or effectively reduced by the traditional approach to maintenance, led Aircraft design engineers for many years to develop design features that mitigated failure consequences. That is they learned how to design aircraft that were in many respects “ failure tolerant”. Practices such as replication of system functions, multiple engines and damage tolerant structures are the order of the day. This has resulted in tens of thousands of items in a transport aircraft, whose failures have no impact on the equipment as a whole. It is less expensive to leave them in service until they fail, than it would be to prevent the failures. In addition, the percentage of human error type failures has

http://www.plant-maintenance.com/articles/uptime.shtml (1 of 5) [5/15/2004 10:19:30 AM] Uptime at Minimum Cost in the Process Industries been significantly reduced by the entrenchment of a disciplined “Best Practice” culture. This coupled to the fact that RCM is a prior to service approach to developing a maintenance program for new aircraft, invariable means that funds, time and access to specialist resources to perform these time consuming analysis are not deemed a problem.

Continuous Process Industry If we compare some of the differences between the Airlines and the Continuous Process Industry, some notable differences come to mind. Our design practices generally lag far behind in that functional replication is rare, time and resources are at a premium, support documentation is deficient in many areas and most equipment is in use and operating in a non-best practice environment, resulting in many different types of root causes. In addition, production at all costs tends to be the driving force for many maintenance decisions, with a lack of understanding of modern maintenance philosophies and practices at most levels of the industry.

MAINTENANCE TASK ANALYSIS PROCEDURE If we accept that the design characteristics coupled to the operating context and the age reliability characteristics determine the preventive maintenance program, then the prescribed RCM functional analytical approach, used in Aviation to safeguard the essential functions of new aircraft (until we have learned enough about the failure process to maintain it correctly) is in-appropriate in its pure form for “in-use equipment” in the process industry, where operating data is available.

Given the differences identified, a customized method for non-aviation application was developed (Refer to attached diagram: ‘Customized Analysis Procedure’) to realize the inherent reliability of in-use equipment at minimum cost. At the outset, given the operating data available, the lack of functional replication for the majority of in-use equipment and the need to accelerate the analysis phase, the up front pre-identification of equipment functions and functional failure modes was dispensed with.

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In its place, following the normal steps of Process mapping (Partitioning), benchmarking, and identification of the maintenance significant items, a powerful screening process based on a customized form of Fault tree analysis is used to screen the failure causes for root causes. Resolution of these ‘non-machine parts root causes’ identified, namely Man, Method, Material and Measurement, in many cases often had a greater impact on bottom line profits than the implementation of the new preventive schedules. This was particularly true in the paper/pulp industry.

For the ‘machine parts root causes’ namely wear and other normal forms of deterioration, the loss of function associated with these root causes is taken through a customized version of the MSG-3 decision logic to establish the appropriate effects category. The root causes are then further subjected to a questioning process to select the appropriate task or tasks for implementation. This part of the logic diagram has been modified to accommodate the significant advantage we in the process industry have, namely the ability of the manufacturing team to visually inspect our equipment in its dynamic mode (For a craftsman in aviation to perform a daily check whilst the aircraft is in flight, would do little for morale).

Adopting this customized approach as permitted a rapid implementation of reliability based maintenance programs for in-use equipment. In the brewing industry, annual shut down maintenance periods of four to six weeks have been reduced to ten days with a sustained improvement in Packaging Line efficiences and reduction in maintenance costs. A similar pattern is emerging in our Paper/Pulp plants. Other benefits that

http://www.plant-maintenance.com/articles/uptime.shtml (3 of 5) [5/15/2004 10:19:30 AM] Uptime at Minimum Cost in the Process Industries have accrued are a change in culture from Reactive to Pro-active Maintenance, the emergence of a powerful continuous improvement ethic based on locally developed root cause analysis techniques and the ability to realise a quantifiable return on our SAP R/3 Computerized Maintenance Management System (CMMS). In addition a reliability based maintenance program cannot add value unless its associated synergistic elements are in place to support (Refer to attached diagram: Maintenance and Logistics).

CONCLUSION

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In conclusion, to achieve the desired behavior changes in the organization to accept this new way of doing business, particularly as one expands the “silo based approach of RCM “ to accommodate focus on the other major machine loss areas, the needs of autonomous maintenance and accurate capture / use of reliability information requires a major paradigm shift by all concerned. Companies need to challenge traditional training methods. Action based learning linked to “real life” equipment assignments, followed up by no warning “simulation” type audits, are vital if we are to be successful in reaping the benefits of modern maintenance in the continuous process industry of the new millenium.

http://www.plant-maintenance.com/articles/uptime.shtml (5 of 5) [5/15/2004 10:19:30 AM] Visual Systems - Sistemas Visuales Visual Systems for Improving Equipment Effectiveness

By Robert M. Williamson

Strategic Work Systems, Inc.

Imagine reducing your equipment-specific training time by 60 to 70 percent and eliminating equipment errors. It is possible by using some easy techniques, known as "visual systems" or "visual signals" that communicate specific information quickly at the point of use on and near the equipment. Equipment effectiveness can be improved significantly by:

● Determining what kinds of critical information will make the equipment easier to operate, maintain, and inspect ● Determining the correct information and a reliable application method ● Applying the critical information

Some examples of visual systems for improving equipment effectiveness include applications:

● On the equipment ● In the spare parts room ● In the area near the equipment ● Visual procedures and work instructions On the Equipment http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/visualsysts.htm (1 of 7) [5/15/2004 10:21:34 AM] Visual Systems - Sistemas Visuales

● Marking the proper operating ranges on temperature, pressure, flow, and speed gauges (Figure 1) ● Labeling equipment components to take the mystery out of nomenclature and maintain accurate equipment repair history ● Labeling lubrication and fluid fill points (Figure 4) ● Marking directions of flow, feed, or rotation to prevent installation errors ● Applying temperature-sensitive recording labels to critical machine components to provide a 24-hour-a-day visual monitoring of hydraulics, electrical components, bearings, motors, etc. ● Using color-coded grease fitting caps to protect and designate lubrication types and frequency ● Permanently attaching vibration analysis pickup discs to equipment and applying identification labels for reliable and repeatable vibration monitoring ● Labeling replacement belt, filter, chain sizes and part numbers on the equipment to save time looking up replacement part numbers ● Color-coding setup and changeover parts for specific product sizes ● Using problem tags to pinpoint the location of machine problems and to request maintenance using a visual "action board" (Figure 2) ● Labeling pneumatic lines and devices to aid troubleshooting ● Labeling electrical and electronic wiring and devices to aid troubleshooting ● Match-marking nuts and bolts to visually indicate that proper tightness is being maintained ● Labeling inspection points and gauge reading sequence numbers (Figures 1 & 3)

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FIG # 1 GAUGES WITH OPERATING RANGES FIG # 2 PROBLEM TAG

FIG # 4 CLEAR MARKINGS ELIMINATE ERRORS

FIG # 3 WHAT ARE WE READING? IN WHAT ORDER? In the Spare Parts Room

● Using shaft targets as a reminder to rotate motor and fan shafts while in storage to prevent "false brinelling" of bearings and armature sag due to lack of rotation ● Inventory control cards with photograph of parts, part numbers, lead time for re-ordering, supplier or source, minimum/maximum levels ● Reorder signal cards placed at the minimum inventory level

http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/visualsysts.htm (3 of 7) [5/15/2004 10:21:34 AM] Visual Systems - Sistemas Visuales In the Area near the Equipment

● Equipment action boards in the plant communicate performance trends and improvements ● Visual preventive maintenance (PM) schedules showing when PMs are due, past due, and completed for the entire year

Visual Procedures and Work Instructions

● Photographs and small drawings used to show important points in procedures ● Photographs used to show where to inspect or adjust ● Photographs used to show where to get equipment readings for a shift inspection log sheet (Figure 5)

Visual systems for improving equipment effectiveness are an extension of the "visual factory" or the "visual workplace." Where the visual factory deals with workplace organization and orderliness to eliminate waste and mistakes, the visuals applied to the equipment truly make them easier to operate, maintain, and inspect.

For more information, see the second edition of the book Visual Systems for Improving Equipment Effectiveness by Robert M. Williamson. Visit Strategic Work Systems' web site or call (864) 234-3100. Strategic Work Systems also offers many visual systems supplies, such as gauge marking labels, problem tags, and grease fitting caps. See the web site for more details or call for a catalog. About the Author

Robert (Bob) Williamson is a workplace educator with more than 30 years or experience helping companies and workgroups improve the performance of their equipment and work processes through applied education and training. His

http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/visualsysts.htm (4 of 7) [5/15/2004 10:21:34 AM] Visual Systems - Sistemas Visuales background in maintenance mechanics, special machine design, and teaching vocational/technical courses has prepared him for a career that has taken him into well over 300 plant and company locations assisting with operations and maintenance training, Total Productive Maintenance development, multi-skill maintenance job design, and pay-for-applied skills design. He formed Strategic Work Systems in 1992 to focus on the people-side of world class manufacturing and maintenance.

Strategic Work Systems, Inc.

Mill Spring, North Carolina 28756 U.S.A.

FIG # 5 EXAMPLE OF MANUFACTURER'S DIAGRAM WITH INDICATIONS

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Visual Systems for Improving Equipment Effectiveness

Click to: OSHA COLOR CODE for piping and other uses

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http://www.tpmonline.com/articles_on_total_productive_maintenance/tpm/visualsysts.htm (7 of 7) [5/15/2004 10:21:34 AM] William Edwards Deming, a Man From Another World W. Edwards Deming, His 14 Recommendations Changed the History of Japan and The World!

By Enrique Mora

W. Edwards Deming conducted a thriving worldwide consulting practice for more than forty years. His clients included manufacturing companies, telephone companies, railways, carriers of motor freight, consumer researchers, census methodologists, hospitals, legal firms, government agencies, and research organizations in universities and in industry.

The impact of Dr. Deming's teachings on American manufacturing and service organizations has been profound. He led a sweeping quality revolution that is improving the competitive position of the United States.

President Reagan awarded the National Medal of Technology to Dr.

http://www.tpmonline.com/articles_on_total_productive_maintenance/management/deming14steps.htm (1 of 8) [5/15/2004 10:21:49 AM] William Edwards Deming, a Man From Another World Deming in 1987. He received in 1988 the Distinguished Career in Science award from the National Academy of Sciences.

Dr. Deming received many other awards, including the Shewhart Medal from the American Society for Quality Control in 1956 and the Samuel S. Wilks Award from the American Statistical Association in 1983.

The Metropolitan section of the American Statistical Association established in 1980 the annual Deming Prize for improvement of quality and productivity. Dr. Deming was a member of the International Statistical Institute. He was elected in 1983 to the National Academy of Engineering, and in 1986 to the Science and Technology Hall of Fame in Dayton. He was inducted into the Automotive Hall of Fame in 1991.

Dr. Deming is perhaps best known for his work in Japan, where from 1950 and onward he taught top management and engineers methods for management of quality. This teaching dramatically altered the economy of Japan. In recognition of his contributions, the Union of Japanese Science and Engineering (JUSE) instituted the annual Deming Prizes for achievements in quality and dependability of product. The Emperor of Japan awarded to Dr. Deming in 1960 the Second Order Medal of the Sacred Treasure.

Dr. Deming received his doctorate in mathematical physics from Yale University in 1928. A number of universities have awarded to him the degrees LL.D. and Sc.D. honoris causa: the University of Wyoming, Rivier College, the University of Maryland, Ohio State University, Clarkson College of Technology, Miami University, George Washington University, the University of Colorado, Fordham University, the University of Alabama, Oregon State University, the American University, the University of South Carolina, Yale University, Harvard University, Cleary College, and Shenandoah University. Yale University awarded to him also the

http://www.tpmonline.com/articles_on_total_productive_maintenance/management/deming14steps.htm (2 of 8) [5/15/2004 10:21:49 AM] William Edwards Deming, a Man From Another World Wilbur Lucius Cross Medal. Rivier College awarded to him the Madeleine of Jesus Award.

Dr. Deming is the author of several books and about 200 papers. His books, "Out of the Crisis" (MIT/CAES, 1986) and "The New Economics" (MIT/CAES, 1994) have been translated into several foreign languages. Hundreds, perhaps thousands of books, films, and videotapes profile his life, his philosophy, and the successful application of his teachings worldwide. Dr. Deming's four-day seminars reached 10,000 people per year for over ten years..

Consider the implementation of Deming's 14 Points for Management

In his book: "Out of the Crisis", Dr. W. Edwards Deming shows these 14 steps toward an improved management. It is not easy in the American Culture to establish such changes. Perhaps that barrier is keeping the American Industry from achieving as impressive results as the ones reached by the Japanese.

http://www.tpmonline.com/articles_on_total_productive_maintenance/management/deming14steps.htm (3 of 8) [5/15/2004 10:21:49 AM] William Edwards Deming, a Man From Another World 1. Create constancy of purpose for improvement of product and service with the aim to become competitive and to stay in business, and to keep providing jobs.

2. Adopt the new philosophy. We are in a new economic age. Western management must awaken to the challenge, must learn their responsibilities, and take on leadership for change.

3. Cease dependence on inspection to achieve quality. Eliminate the need for inspection on a mass basis by building quality into the product in the first place.

4. End the practice of awarding business on the basis of price tag. Instead, minimize total cost. Move toward a single supplier for any one item, on a long- term relationship of loyalty and trust.

http://www.tpmonline.com/articles_on_total_productive_maintenance/management/deming14steps.htm (4 of 8) [5/15/2004 10:21:49 AM] William Edwards Deming, a Man From Another World 5. Improve constantly and forever every process for planning, production and service. Improve quality and productivity, and thus constantly decrease costs.

6. Institute training on the job. This should be a part of everybody's everyday's activities. 7. Adopt and institute leadership. The aim of supervision should be to help people and machines and gadgets to do a better job. Supervision of management is in need of overhaul as well as supervision of production workers.

8. Drive out fear so that everyone may work effectively for the company because they want it to succeed.

9. Break down barriers between staff areas or departments. People in research, design, sales, and production must work as a team, to foresee problems of production and in use that may be encountered with the product or service.

http://www.tpmonline.com/articles_on_total_productive_maintenance/management/deming14steps.htm (5 of 8) [5/15/2004 10:21:49 AM] William Edwards Deming, a Man From Another World 10. Eliminate slogans, exhortations and targets for the workforce asking for zero defects and new levels of productivity. Such exhortations only create adversarial relationships, as the bulk of the causes of low quality and low productivity belong to the system and thus lie beyond the power of the work force.

11. Eliminate numerical quotas for the workforce and numerical goals for management. a. Eliminate work standards (quotas) on the factory floor. Substitute leadership. b. Eliminate the obsolete concept of "management by objective". Eliminate management by numbers, numerical goals. Substitute leadership.

12. Remove barriers that rob people of pride of workmanship--eliminate the annual rating or merit system. a. Remove barriers that rob the hourly worker of his right to pride of workmanship. The responsibility of supervisors must be changed from sheer numbers to

http://www.tpmonline.com/articles_on_total_productive_maintenance/management/deming14steps.htm (6 of 8) [5/15/2004 10:21:49 AM] William Edwards Deming, a Man From Another World quality. b. Remove barriers that rob people in management and in engineering of their right to pride of workmanship. This means, inter alia, abolishment of the annual merit rating and of management by objectives.

13. Institute a vigorous program of education and self- improvement for everyone. Let them participate to choose the areas of development.

14. Put everybody in the company to work to accomplish the transformation. The transformation is everybody's job.

FROM THE WEBMASTER: IT IS NOT OUR INTENTION TO DISTURB THE PEACE IN YOUR BUSINESS ENVIRONMENT. DEMING, THOUGH, HAS BEEN CONSIDERED A VISIONARY AND HIS WORDS SHOULD BE CONSIDERED SERIOUSLY AS THE RULINGS FOR THE FUTURE.

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http://www.tpmonline.com/articles_on_total_productive_maintenance/management/deming14steps.htm (8 of 8) [5/15/2004 10:21:49 AM] What is Total Productive Maintenance?

What is Total Productive Maintenance?

The modern view of maintenance is that it is all about preserving the functions of physical assets. In other words, carrying out tasks that serve the central purpose of ensuring that our machines are capable of doing what the users want them to do, when they want them to do it. The possible maintenance policies can be grouped under four headings viz.

1. Corrective - wait until a failure occurs and then remedy the situation (restoring the asset to productive capability) as quickly as possible.

2. Preventive - believe that a regular maintenance attention will keep an otherwise troublesome failure mode at bay.

3. Predictive - rather than looking at a calendar and assessing what attention the equipment needs, we should examine the 'vital signs' and infer what the equipment is trying to tell us. The term 'Condition Monitoring' has come to mean using a piece of technology (most often a vibration analyser) to assess the health of our plant and equipment.

4. Detective - applies to the types of devices that only need to work when required and do not tell us when they are in the failed state e.g. a fire alarm or smoke detector. They generally require a periodic functional check to ascertain that they are still working.

Apart from detective maintenance, the central problem that companies have struggled with is how to make the choice between the other three. This has led to the increasing interest within industry in two strategies, which offer a path to long term continuous improvement rather than the promise of a quick fix. These are Reliability Centred Maintenance (RCM) and Total Productive Maintenance (TPM). The two strategies, although having similar names, actually have very different strengths. RCM has been fully described while TPM will now be discussed.

TPM is a manufacturing led initiative that emphasises the importance of people, a 'can do' and 'continuous improvement' philosophy and the importance of production and maintenance staff working together. It is presented as a key part of an overall manufacturing philosophy. In essence, TPM seeks to reshape the organisation to liberate its own potential.

The modern business world is a rapidly changing environment, so the http://www.maint2k.com/what-is-tpm.html (1 of 4) [5/15/2004 10:22:15 AM] What is Total Productive Maintenance?

last thing a company needs if it is to compete in the global marketplace is to get in its own way because of the way in which it approaches the business of looking after its income generating physical assets. So, TPM is concerned with the fundamental rethink of business processes to achieve improvements in cost, quality, speed etc. It encourages radical changes, such as;

● flatter organisational structures - fewer managers, empowered teams,

● multi-skilled workforce,

● rigorous reappraisal of the way things are done - often with the goal of simplification.

It also places these changes within a culture of betterment underpinned by continuous improvement monitored through the use of appropriate measurement. The principal measure is known as the Overall Equipment Effectiveness (OEE). This figure ties the 'six big losses' :

1. Equipment Downtime 2. Engineering Adjustment 3. Minor Stoppages 4. Unplanned Breaks 5. Time spent making reject product 6. Waste

to three measurables:

Availability (Time), Performance (Speed) & Yield (Quality).

When the losses from Time X Speed X Quality are multiplied together, the resulting OEE figure shows the performance of any equipment or product line.

TPM sites are encouraged to both set goals for OEE and measure deviations from these. Problem solving groups then seek to eliminate difficulties and enhance performance.

TPM achievements

Many TPM sites have made excellent progress in a number of areas. These include:

● better understanding of the performance of their equipment (what they are achieving in OEE terms and what the reasons are for non-achievement),

http://www.maint2k.com/what-is-tpm.html (2 of 4) [5/15/2004 10:22:15 AM] What is Total Productive Maintenance?

● better understanding of equipment criticality and where it is worth deploying improvement effort and potential benefits,

● improved teamwork and a less adversarial approach between Production and Maintenance,

● improved procedures for changeovers and set-ups, carrying out frequent maintenance tasks, better training of operators and maintainers, which all lead to reduced costs and better service,

● general increased enthusiasm from involvement of the workforce.

However the central paradox of the whole TPM Process is that, given that TPM is supposed to be about doing better maintenance, why do proponents end up with (largely) the same discredited schedules that they had already (albeit now being done by different people)? This is the central paradox - yes, the organisation is more empowered, and re-shaped to allow us to carry out maintenance in the modern arena, but we're still left with the problem of what maintenance should be done.

The RCM process was evolved within the civil aviation industry to fulfil this precise need. In fact, the definition of RCM is "a process used to determine the maintenance requirements of physical assets in their present operating context". In essence, we have two objectives; determine the maintenance requirements of the physical assets within their current operating context, and then ensure that these requirements are met as cheaply and effectively as possible.

RCM is better at delivering objective one; TPM focuses on objective two.

Can the techniques be deployed together?

The answer depends on what 'brand' of RCM is being considered. The 'hired gun' or 'magic box' approach will never be compatible with TPM. RCM must be performed by the organisation itself. The sole focus must be to teach organisations to analyse their own assets. In this way, empowered teams remain empowered, ownership is retained and enhanced and companies begin to win the asset management battle.

Your company can also benefit from TPM. Our 2 day TPM seminar will show you exactly how.

See what others have to say about our training seminars here.

Contact [email protected]

Click here to bookmark this page.

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http://www.maint2k.com/what-is-tpm.html (4 of 4) [5/15/2004 10:22:15 AM] A New Generation of Condition Monitoring And Diagnostic Systems A New Generation of Condition Monitoring And Diagnostic Systems

Alexei Barkov and Anton Azovtsev

Abstract

Continuous monitoring of the processes in the operating machinery has always been considered as one of the most efficient methods for machine condition assessment. Recently, a major step forward in the development of microprocessor and signal analysis technology has occurred that allows the development of powerful, efficient, and, at the same time relatively in-expensive systems for continuous condition monitoring of different machine parameters. These systems have become widely used in many enterprises and now, the market-place shows continuously growing demand for such systems. Older systems have only been able to detect changes in vibration levels and patterns but not the reasons for the changes. Until now, this problem has been solved by the efforts of a limited number of very qualified experts in condition diagnostics and this fact has resulted in limited distribution of the technology in the industry. This situation has begun changing recently as a result of major steps forward in the development of condition diagnostics methods for machinery which include significant increases in the ability to define defects that can be detected in the incipient stage of their development as well as automation of the condition diagnostics process. As a result, the experts’ productivity has been significantly increased and, in many standard situations, the experts have been replaced by specialized diagnostics software programs

A new generation of such systems is described below. Such a system for rotating machinery condition monitoring and diagnostics using vibration analysis combines all the modern condition monitoring and diagnostic methods and the latest developments of microprocessor and computer techniques. This generation of the systems may be recognized by the automatic condition diagnostics of particular machine units allowing reliable operation of the machine, not by continuous condition monitoring, but by intermittent monitoring with intervals between measurements up to weeks or even months. The main emphasis is applied to portable, off-line systems that allow condition monitoring of hundreds of machines, thus decreasing the expense on condition monitoring and diagnostics by orders of magnitude.

Monitoring and Diagnostics Tasks

The main task of the machine vibration monitoring system was previously the monitoring of the vibration parameters chosen either by the machinery designers or users with the purpose of detecting changes in machine operating conditions. The new systems, despite that they are usually referred to as condition monitoring systems, can have new tasks including machine vibration monitoring and intervention in the operation of the machinery. Vibration monitoring, in turn, may include the comparison of the machine vibration parameters with the parameters of a group of other identical machines, i.e. monitoring by a set.

The tasks that had been stated for the new generation of condition monitoring and diagnostics systems can be divided into three main groups:

● The first group includes the traditional tasks for vibration state development monitoring and prediction for machines or their units operating in standard conditions. This is usually done using permanent measurement systems installed in the most important machines and equipment. The standard modes not necessarily are limited to stable conditions, but may include startup and transition modes as well. ● The second group is the tasks connected with the comparison analysis for a group of identical objects. These can be, not only the machines, but also their units as well as the equipment that is not a source of relevant vibration. In the latter case, the vibration can be excited by external sources of vibration including, for example, shocks. Typically, these are the tasks of final tests of manufactured or repaired products and is usually done by condition monitoring systems installed in the test stands which is why they are referred to as the test stand condition monitoring systems. ● The third group of tasks is defined by the abilities of condition diagnostics. This is the monitoring of detected defects development starting from their incipient stage when the traditional condition monitoring systems do not identify the vibration changes as a machine defect. Typically, these defects occur either immediately after machine manufacturing (installation) or during the first half of service life during the initial stage of particular machine unit wear. This type of machine condition monitoring provides long term condition prediction for the non-failure machine operation period and residual service life after development of severe defects.

For several years, vibroacoustical machine condition diagnostics developed in two directions - as a part of condition monitoring and as

http://www.vibrotek.com/articles/newgen/ (1 of 9) [5/15/2004 10:31:59 AM] A New Generation of Condition Monitoring And Diagnostic Systems a standalone direction aimed at the detection and identification of defects.

Today, the detailed condition diagnostics methods allow detection of most incipient defects before the vibration state of machine changes. This fact inspired the development of a new generation of condition monitoring and diagnostics systems. As a result, the tasks of such systems undertook considerable changes. In particular, primary attention was focused on the each machine unit condition assessment and the integral estimation of the condition of the machine as a whole was based on the conditions of all the machine units. More attention was paid to the high frequency vibration component measurements and, consequently, the acceleration signals rather than velocity or displacement.

The main tasks for condition diagnostics, both functionally without any changes in machine operation mode and in testing under the influence of external controlled vibration exciters, also can be divided into three main groups. This division is based on the method used for determining diagnostics standards. These standards are used for defect detection, identification, and development prediction.

The first group uses standards based on a group of consecutive measurements of diagnostic signals for each machine (history based standard). These methods were traditionally used in condition monitoring systems and the main type of vibration signal analysis was narrow band spectrum analysis.

The second group of tasks used the standards formed by single vibration measurements conducted on a group of identical machines’ units (set based standard). These tasks are typical for the final output control at repair or production shops. A number of signal analysis techniques can be applied in this connection, but the most powerful method is similar to the previous case using spectrum analysis of the vibration signal.

The third group contains the tasks with the most complex solutions for development, but are most efficient in practical diagnostics with prior known standards. Thus condition diagnostics can be done using a single vibration measurement. Typically, the solution of most complicated problems is based on the analysis of signal modulation processes, for example, using the spectrum analysis of low frequency oscillations of high frequency signal power, including vibration excited by periodic shock pulses. In this case the standard of the defect free state is most typically considered the absence of certain features in the analyzed signal.

The new generation of condition monitoring and diagnostics systems reliably detect, not only potentially dangerous defects of any of above groups at the initial stage of their development, but also identify the exact defect type and its severity. Only in this case and, taking into account prior known development rates for each of defect types, is it possible to provide long term condition prediction and residual service life of the machine or its unit. This task is considered to be the main one for the new generation of the condition monitoring and diagnostics systems.

Methods of Diagnostics

The increased number of tasks available in the new generation of condition monitoring and diagnostics systems has resulted in advances in both existing diagnostic technology and the development of new diagnostic and condition monitoring methods.

The main signal analysis method for rotating machinery condition monitoring is still narrow band spectrum analysis of vibration and noise signals. Among the new technical solutions are automatic spectra processing with the extraction of harmonic components and detection of their amplitudes and frequencies as well as their possible origin. Such automation allows much more reliable trending of the signal component development and predicts their changes, especially in cases of fluctuations of the rotation speed from measurement to measurement.

http://www.vibrotek.com/articles/newgen/ (2 of 9) [5/15/2004 10:31:59 AM] A New Generation of Condition Monitoring And Diagnostic Systems

Fig.1. Autospectrum with the alarm level. When the spectrum exceeds the alarm level condition monitoring system issues an alarm signal. Usually the alarm levels are entered by the operator according to his experience and machinery design specifications.

Another important point is separation of condition monitoring of a machine as a whole versus its particular units. In the first case, the measurement points are distant from the primary vibrating units and close to the less noisy ones and condition monitoring is done mainly by the analysis of low and medium frequency vibration. In the other case, the measurement points are chosen directly on the monitored unit case and condition monitoring is combined with diagnostics. Here, most attention is paid to the high frequency vibration.

New methods of comparative vibration signal parameters analysis are developed for the final test control after machine assembly or repair, i.e. for condition monitoring by a set. The best way to form and adapt a vibration state standard for new generation condition monitoring and diagnostics systems is to do it jointly with condition diagnostics when only the machines with no severe defects detected by diagnostic routines are used to form vibration state standards. Condition monitoring by a set has one more peculiarity. It is possible use of external vibration exciters or shakers, especially in cases when the unit under control does not generate vibration while the test measurements are being performed.

Principally, a new technical solution in the new generation condition monitoring and diagnostics systems is the monitoring of machine or machine unit technical condition. To do so using each of vibration measurement, the automatic diagnostic system makes a condition diagnosis with identification of all possible defects, even in their incipient stage. Next each defect is monitored during its development. This approach allows the prediction of defect development and the accurate prediction of residual service life for the machine or its unit.

The condition diagnostics methods used in the first generation condition diagnostics systems were very restricted in their abilities. So, the software programs were developed as expert systems that helped the operator to manage the results of measurements made with the purpose of optimization of the further accumulation of data and the choice of the most probable diagnosis from many suggested by the expert system. The final results, as usual, were uncertain and the diagnosis quality was defined by the level of operator qualification, the abilities of measurement instrumentation, and the amount of work necessary to obtain additional information.

http://www.vibrotek.com/articles/newgen/ (3 of 9) [5/15/2004 10:31:59 AM] A New Generation of Condition Monitoring And Diagnostic Systems

Fig.2. Envelope spectrum of a bearing shield high frequency vibration components. Envelope analysis is a very informative condition diagnostics tool. If there are no harmonic components in the envelope spectrum then there are no defects in the machine unit. If there are some harmonics, then their frequencies say what is the defect type and the amplitude of them above the background level (DL) reveals the defect severity.

The further development of condition diagnostic systems was happening in two ways. These differed in their options for the customer to correct and enter new diagnostic symptoms according to his experience and the characteristics of the machines under diagnostics.

The existing first generation systems are completely open ones, and the customer can enter any parameters and symptoms he would like to use in diagnostics to detect and identify defects. Typically, the designers limit the customers only in the changes of the software routines for state recognition, but the knowledge bases can be edited by the customers by entering defect symptoms and rules for their recognition. Of course, the established standard rules are preloaded in these databases and the customer initially has to select the ones to be applied for his problems.

This type of systems has its own advantages and disadvantages. Its main advantage is the ability to be adapted to both diagnostic objects and measurement instrumentation available for the customer. The adaptation can only be done by a highly qualified expert so that contradictory rules or very high weight coefficients for the rules that give rather high errors are not entered. The volume of such work is very high and practical use of this system for condition diagnostics may only begin after several months of system adaptation.

The previous statement reveals the main disadvantages of open systems. Besides the huge amount of work required for the system adaptation, such a system requires a lot of work to make additional diagnostic measurements not used in condition monitoring, and then entering them into the main expert database. Such measurements are typically needed to increase the diagnostics reliability.

The second approach to the condition monitoring and diagnostics systems development is the closed type of diagnostic structure. In this case, all diagnostic rules are chosen and tested by the developers of the system and the system itself is optimized for the selected types of measurements. These systems are oriented to the condition diagnostics of standard machines or their units, e.g. bearings, gears, impellers, etc. Operating such a system does not require any user training in vibration analysis or condition diagnostics as all the measurements, data transfer and condition diagnostics are automated. The fact that these systems are specialized for certain diagnostic measurements results in minimum prices and maximum possible productivity and efficiency of the system.

The weak point of this approach is that, in those rare cases when the system needs adaptation for very specific machines or their units, the customers must ask the system developers to develop or supply non-standard diagnostic modules. This situation was observed in cases of machines where it is impossible to attach vibration transducers on the diagnostic unit housing. In this case, special diagnostic modules are developed. These modules usually use the same measurements to make condition diagnostics of several machine units installed in one housing. As an example, we can mention a task that we have done for the development of modules for rolling element bearings condition diagnostics in the aircraft jet engine. The points needed to make measurements on the bearing housing were not available and the solution was found in the simultaneous condition diagnostics of the bearings and working wheels of turbines and compressors.

The development of condition diagnostic modules for standard machine units is a rather difficult problem. Despite the use of known

http://www.vibrotek.com/articles/newgen/ (4 of 9) [5/15/2004 10:31:59 AM] A New Generation of Condition Monitoring And Diagnostic Systems diagnostic methods, it takes several years to develop a reliable automatic module that usually becomes the proprietary knowledge of the developers. As a result, the diagnostics efficiency and reliability greatly depend on the choice of the company that developed the condition diagnostic modules and not the company that produced measurement instrumentation and diagnostic system.

A short description of physical processes behind the most efficient diagnostic methods for rotating machines is presented below. These methods are used by the experts of VAST, Inc. (Russia) and Inteltech Enterprises, Inc. (USA) in the development of diagnostic modules used in the new generation condition monitoring and diagnostics systems.

The condition diagnostics of bearings is done by the analysis of low frequency fluctuations of friction forces and the power of the high frequency vibration excited by them. To do so, the spectrum of high frequency vibration power oscillations is measured, i.e. spectrum of high frequency vibration envelope.

Condition diagnosis of geared, chain, worm, and other types of mechanical transmissions is done using the analysis of shock loads occurring in the gear interaction which are transferred to the bearings of the transmission. The shock loads in the transmission can be both positive loads that increase the load on the bearings and negative loads that decrease the bearing load. The changes in loads are also detected by the analysis of vibration envelope spectra measured on the bearings housing.

Condition diagnostics of working wheels rotating in the gas or fluid flow is done by the appearance of an increased turbulence "cloud" in the flow which can either rotate together with the defective blade or appear periodically in the defect zone on the stationary inner surface of the machine body. The properties of this turbulence "cloud" can be analyzed by the envelope spectra of the high frequency noise of the flow or vibration of the machine (pipeline) body excited by the flow.

Defects of electric machines (electromagnetic system of the machine) are found from the appearance of pulsating torque in the machine. This torque may pulsate at different frequencies and may result in changes of machine vibration patterns at a number of machine points and directions. For the identification of these torque symptoms, we use autospectra of the machine body vibration.

Diagnostic modules for other standard rotating machines’ units are developed on basis of more complicated physical models that include simultaneous influence of several physical processes. The more detailed information about the physical basis of the rotating machine vibration diagnostics was published in a number of papers [1,2].

System Configuration

The configuration of condition monitoring and diagnostics systems is defined by the choices of means for measurements and physical process analysis and by the configuration of the software package. Thus, from the measurement instrumentation the systems can be divided into three main types - portable, stand and stationary.

The first type uses portable measurement instrumentation for the measurements and analysis of vibration, noise, temperature, current, etc. The systems of the second type are usually a part of different temporary test stands. As usual, transducers are temporarily mounted at the measurement points for the time required for measurements and diagnostics. The third type is stationary condition monitoring and diagnostic systems that operate together with the diagnosed object and continuously monitor its condition. Transducers are permanently installed in the diagnosed object together with the signal and communication lines that are connected to the measurement instrumentation, monitoring and diagnostics system.

Some of the systems used for practical diagnostics can have extended capabilities combined from different types of systems. Thus, it is very often that portable condition monitoring and diagnostics systems are used together with transducers permanently mounted in inaccessible points with signal lines brought to accessible places. Some times, stationary systems are equipped with portable measurement instruments to obtain measurements in additional measurement points.

http://www.vibrotek.com/articles/newgen/ (5 of 9) [5/15/2004 10:32:00 AM] A New Generation of Condition Monitoring And Diagnostic Systems

Fig.3. Portable condition monitoring and diagnostic system consists of a personal computer with software for automatic condition diagnostics and monitoring and a portable data collector, for example the DC-11 (at the picture)

Figure 3 illustrates the configuration of a typical portable condition monitoring and diagnostics system produced in Russia for several years. Besides vibration transducers, other types of transducers can be used in this system. Such a system can also include special devices for test diagnostics such as voltage sources for assessing the condition of electrical isolation, exciters for different assembly diagnostics, and so fourth.

Fig.4. Stand condition diagnostics and monitoring system consists of a personal computer equipped with an ADC boards and interfacing circuits to vibration sensors and photoprobe. Here is an example of the system based on portable computer and it can be taken to the object for diagnostics. This system has 8-16 channels

Figure 4 presents a stand system for vibration monitoring and condition diagnostics. This system is based on a portable computer having an analog to digital converter, digital signal processor, and an interface for up to 16 accelerometers and a tachometer probe.

http://www.vibrotek.com/articles/newgen/ (6 of 9) [5/15/2004 10:32:00 AM] A New Generation of Condition Monitoring And Diagnostic Systems

Fig.5. Stationary condition diagnostics and monitoring system typically consists of a personal computer or a diagnostic station connected to signal commutation and conditioning blocks and then vibration and rotation speed sensors. The number of channels and measurement points in such a system may be from a few ones up to several hundreds.

Figure 5 presents a typical configuration of a stationary system that differs from the first stand by the presence of additional commutation and preliminary signal conditioning blocks.

The software for condition monitoring and diagnostics systems consists of three main modules. The first one is the signal analysis, the second one is condition monitoring and the third module makes condition diagnostics and prediction. Each of software modules may have several ranges of complexity that is defined by the tasks of the system.

The lowest level of software complexity is found in systems used for alarm condition monitoring. Their main task is to shut down the machine (equipment) when the vibration level (power) or the level of some vibration components exceeds the specified allowed levels. The most difficult part of such a system is the choice of measurement system, taking into account reasonable pricing and the ability to do continuos vibration monitoring.

Often the condition monitoring systems having vibration state prediction capability possess one of the most complex software systems for signal analysis and condition monitoring. At the same time, the condition diagnostics modules are at rather low level in this type of system; typically this is an expert system that helps in the interpretation of monitoring measurement results.

The highest level of condition diagnostics software posses the detailed diagnostics systems that are aimed on the incipient defects detection and defect development monitoring with machine (machine unit) condition and residual service life prediction. But most of these systems do not have the most advanced signal analysis and condition monitoring modules as the tasks for the vibration monitoring are not so complex in these systems and all types of vibration analysis are standard.

Currently, a number of companies are planning to introduce new software for the condition monitoring and diagnostics systems where all the three modules discussed above are of the highest possible level. Such a system can simultaneously solve all the problems of condition monitoring, diagnostics and prediction. What is of most importance is that it becomes possible to monitor, not only the vibration parameter changes, but also particular defect development. We say that this is a technical condition monitoring, but not just vibration monitoring. A number of problems are solved in these systems by two simultaneous methods; for example, one diagnosis is made using the automatic closed algorithms built in the system and another diagnosis is made using the algorithms chosen by the operator according to his knowledge and experience. As an output, these systems issue two independent recommendations according to the two diagnoses. We think that these types of software packages are the most promising for condition monitoring and diagnostics

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The experience in work with customers

The new generation condition monitoring and diagnostics systems were based on many years experience in the support of the users of condition monitoring systems in Russia. One problem until recently in most enterprises in Russia is the absence, not only of condition monitoring and diagnostics systems, but also experts in this field, measurement instrumentation, and means of physical processes analysis such as for example noise and vibration measurement tools that can be used for condition diagnostics.

Several attempts to introduce condition diagnostics service in enterprises failed first because the top management did not want to invest much money in the training of the staff or to purchase expensive equipment without guaranteed system pay back in a short period of time. To overcome such problems, it was decided to design a condition diagnostics system for a single type of machine unit, the rolling element bearing. The use of such a system should not require any special training from the operator and should pay back the expenses on its installation within a half a year. It took two years to develop such a system, but it was very efficient so we decided to extend the nomenclature of the automatically diagnosed rotating machine units.

After such portable systems started to pay back in three months in very big enterprises, the second stage of condition monitoring and diagnostics introduction was started. A number of customers asked us to install permanent transducers on the most important machinery at the points that can not be accessed during machine operation. The cables were brought up the accessible locations. At the same time in a number of enterprises, special diagnostic teams were organized. These teams had different measurement and analysis instrumentation and had a number of tasks including condition monitoring of the most important machine units where, due to certain circumstances, it was not possible to detect defects in the incipient stage of their development. Together with these customers, we have developed specifications for a new generation of condition monitoring and diagnostics systems. These systems combine all the advantages of the stationary continuos monitoring systems and portable systems for detailed condition diagnostics of rotating machines units.

As the Russian experts did not possess any great experience in vibration monitoring systems, we have joined our efforts with an American company, Inteltech Enterprises, Inc. This has resulted in, for example, development of a new generation of the software for condition monitoring and diagnostics software developed jointly by VAST, Inc. (Russia) and Inteltech Enterprises, Inc. (USA). This software can be used in condition monitoring and diagnostics systems together with measurement instrumentation produced by a number of different companies.

During beta tests of the system in Russia, the customers suggested the separation of the part of the software that could work only with portable instruments without the use of on-line measurements. At the same time, the loss of condition diagnostics and prediction quality and reliability should be minimal.

This work was successfully completed by VAST, Inc. and simultaneously a specialized portable data collector and spectrum analyzer, the DC-11 (figure 3), was developed. Finally, a portable condition monitoring, diagnostics and prediction system or rotating machines with additional possibility of field balancing for rotating machines was developed.

One more result of customer’s experience in work with portable systems in transportation, particularly railways, was the development of test stand systems for condition monitoring and diagnostics for a set of identical objects (figure 4). Experience showed that such a condition diagnostics system used for the wheel cartridges using a single vibration measurement on box bearings, for example, decreases the number of bearings failures by many times. And this is despite the fact that we have wayside condition monitoring systems based on infra-red emission. Thus, it was acknowledged that the periodic condition diagnostics of box bearings with time intervals of about three months allows a decrease of bearings failures much below the previously accepted levels. This system won the competition organized by the federal railway ministry in Russia on the supply of condition diagnostic systems for Russian railways.

Conclusions

1. The new generation of condition monitoring and diagnostics systems differs by the detailed solution of diagnostic problems that allows making a step from machine vibration state monitoring to the monitoring of the machine technical condition. 2. Most rotating machine defects can be detected by such a system much before dangerous situations occur. It allows the efficient use of, not only stationary on-line continuous monitoring systems, but also portable, off-line systems for condition monitoring

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and diagnostics as well. 3. The tendency toward a rapid decrease in the expenses of the condition diagnostics is evident. This allows the introduction of condition diagnostics, not only for the primary, most important equipment, but also for supplementary machinery as well and, thus, more wide introduction of preventive condition based maintenance.

References

1. A. V. Barkov, N. A. Barkova, and A. Yu. Azovtsev, "Condition Monitoring and Diagnostics of Rotating Machines Using Vibration", VAST, Inc., St. Petersburg, Russia, 1997 2. A collection of condition diagnostics papers on the Internet site: http://www.vibrotek.com/ref.htm

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http://www.vibrotek.com/articles/newgen/ (9 of 9) [5/15/2004 10:32:00 AM] alignment, pumps Subject: Pump and driver alignment 14-3

In the pump business alignment means that the centerline of the pump is aligned with the centerline of the driver. Although this alignment was always a consideration with packed pumps, it is critical with sealed pumps especially if you are using rotating seal designs where the springs or bellows rotates with the shaft.

A little misalignment at the power end of the pump is a lot of misalignment at the wet end, and unfortunately that is where the seal is located in most pump applications.

Misalignment will cause many problems:

● It can cause rotating mechanical seals to move back and forth axially two times per revolution. The more the seals move the more opportunity for the lapped faces to open ● Packing could support a misaligned shaft. A mechanical seal cannot. ● Misalignment will cause severe shaft or sleeve fretting if you use spring loaded Teflon® as a secondary seal in your mechanical seal design. ● The pump bearings can become overloaded. ● The misalignment could be severe enough to cause contact between stationary and rotating seal components: ● The wear rings can contact. ● The shaft can contact the restriction bushing often found at the end of the stuffing box. ● The shaft or sleeve can contact the stationery face of the mechanical seal. ● The shaft can contact the disaster bushing in an API (American Petroleum Institute) gland. ● The impeller could contact the volute or back plate.

Regardless of the alignment method you select, you must start with a pump and driver in good repair. A perfectly aligned piece of junk is still a piece of junk. You should also check the following:

● A straight shaft that has been dynamically balanced. ● Good wear rings with the proper clearance. ● The correct impeller to volute, or backplate clearance. ● The elimination of "soft foot". ● Eliminate all pipe strain. ● Good bearings installed on a shaft with the proper finish and tolerances. ● A good mechanical seal set at the proper face load. The closer the seal is to the pump bearings the better off you are going to be.

All pump to driver alignments consist of four parts:

● You must level the pump and driver. If the pump is aligned without being level, the oil level will be incorrect and you will develop bearing problems.

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● You then take a series of radial and axial measurements to see where the pump is located in respect to its driver (motor). ● You make calculations to see how far the driver must be moved to align the centerline of the pump to the centerline of the driver. These calculations must consider that the pump and driver operating temperature will probably be very different than the ambient temperature when you are taking the readings. ● Most pump manufacturers should be able to supply you with the proper readings for a hot alignment. They are the only people that know how their unit expands and contracts with a change in temperature. ● You must now shim and move the driver to get the alignment. Most of the small pump designs are not equipped with "jack bolts" so this will be the most difficult part of the alignment procedure. You cannot move the pump because it is connected to the piping.

I see lots of pumps that have never been aligned properly. When you talk to the people that should be concerned, you get the following comments:

● Alignment is not important. I have been working with pumps for years and we never do it at this facility. And we do not do dynamic balancing of the rotating assembly either! ● There is no time to do an alignment. Production wants the unit back on line, and they will not allow me the time to do it properly. ● We purchase good couplings. The coupling manufacturer states that their coupling can take a reasonable amount of misalignment.

It turns out that there are at least three methods of getting a good pump to driver alignment, and a good coupling is not one of them. The coupling is used to transmit torque to the shaft and compensate for axial thermal growth, nothing else. You install a good coupling after you have made the pump to driver alignment, not instead of making the alignment.

Here are some acceptable methods:

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The reverse indicator method is an acceptable method, but it does take a great deal of time. There are plenty of schools that teach this method if you are interested in learning how to do it:

● Very accurate especially for small diameter flanges ● Not affected by axial float. ● Can be used with a flexible coupling in place. ● You have to rotate both shafts

The laser is the latest method. It is also the most popular. There are lots of people that can teach you to use the equipment, once you have made the purchase.

The "C or D" frame adapter is probably the easiest method of all and available from most quality pump manufacturers It solves most of the problems with thermal expansion.

You use a machined, registered fit to insure the alignment.

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The shaft to coupling spool method:

● The best method when there are big distances between the shaft ends. ● A simple method to use. ● Most people rotate both shafts

Face and rim method:

● Use this method if one of the shafts cannot be rotated. ● An excellent method for large shaft diameters (8 inches or 200mm or greater) or if the diameters are equal to, or greater than the span from the bracket location to the face and rim location where the readings are to be taken. ● Not too good a method if there is axial float from sleeve or journal bearings.

Given a choice I would select the C or D frame every time.

● The "C frame" is for inch sizes The "D frame" for metric sizes. ● Automotive people use the same concept to align an automobile transmission to the engine. They call the adapter a "bell housing". ● The concept was originally developed for the marine industry where it would be impossible to bolt the motor and pump to the deck of the ship, and then do an alignment. The hull flexes making any conventional alignment ineffective. The same logic applies to off shore drilling rigs. ● The adapter does a better job of equalizing the heat transfer between the pump and the driver. It does not all have to conduct through the shaft. ● The adapter is available for all quality end suction centrifugal pumps. Check with your supplier for the availability of one for your pump ● When given a choice, select a ductile rather than a cast adapter. ● Up to about thirty-horse power (22 KW) you hang the motor on the pump. Above thirty-horse power (22 KW) you hang the pump on the motor.

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● The adapter solves the problem of "there is no time to do an alignment". ● If your motor does not have a "C or D" end bell, one can be installed when the motor is rewound. Some, but not all explosion proof motors are available with a C or D frame end bell. Check with your supplier.

If you do not have a C or D frame adapter you will be involved in the last three steps of the four-step procedure.

Once you have made all the measurements, put in the recommended compensation for thermal expansion, and figured out all the calculations for how much to move the driver, and in which direction; now comes the fun part; moving the driver.

You can hit the motor with a big hammer, but small dimensions are hard to get with this method.

Some people use an adjusting wheel that attaches to shims. This will give you a very precise movement that is necessary for a proper alignment

Another method is to use an adjusting wheel that slips over the motor hold down bolts. Many mechanics make there own tools and these units also work very well for precise motor movement.

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How concerned should you be about alignment? You do it on your automobile when you notice uneven tire wear or the car drifts to one side of the road when you loosen your grip on the wheel, and have no problem justifying the cost and time involved. It is the same logic you use towards the added cost and time spent balancing the tires and wheels of your car.

We do not always apply the same logic to our very expensive rotating equipment in the shop, but we should. A mechanical seal should run trouble free until the carbon sacrificial face has worn away. When we inspect the seals we remove from leaking pumps we find that in better than 85% of the cases there is plenty of carbon face left on the seals. The seals are leaking prematurely and the seal movement caused by pump to motor misalignment is a major contributing factor.

Link to Mc Nally home page

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Article Summary:

In theory, machine alignment is a straight-forward process, but in real world applications, it is often compounded by structural faults such as 'soft foot', piping strain, induced frame distortion, excessive bearing clearance or shaft rubs. These pitfalls can turn a simple job into an all day affair - frequently with unsatisfactory results despite a conscientious effort and a considerable investment in manpower and downtime.

Article Details:

It is important to realize that otherwise straight-forward alignment jobs can become highly complex and yield unacceptable results if the technician does not address the quality of the alignment measurement and potential frame stress conditions (frame distortion, soft foot, and piping strain)

during the pre-alignment check. These steps should all be conducted before the technician ever begins to move the machine.

Data quality can be determined by using the validity rule for conventional dial indicator and laser alignment methods, while sweep laser system offer an added level of data qualification by measuring the shaft movement throughout the entire rotation. This added information can help identify not only the existence of a structural problem but also the nature of the problem.

Soft foot and piping strain can be quantified using either the Frame Distortion Index (FDI) or the Laser Soft Foot Locator. FDI looks at the total stress or distortion on the frame caused by vertical movement of the shaft, while the Laser Soft Foot Locator looks at both the vertical and horizontal movement to quantify the need (priority) to fix soft foot before proceeding with the alignment job.

Click here for the complete article. http://www.compsys.com/DRKNOW/APLPAPR.NSF/19fcc759cbee3c3c8525659800528caa/ee9ebeadd87dfc4e85256639004749ee!OpenDocument

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