MAINTENANCE TECHNOLOGY

Monday, 28 May 2012 17:46 - Viewpoint: Questions and Answers — Are you Reliable Enough?

Mon, 28 May 2012 23:46:46 +0100

When I say “reliable,” what do I really mean? A dictionary will define the word as “capable of being dependable.” Synonyms include terms like “trustworthy” and “responsible.” With this in mind, I ask the following question: “Are you reliable?” Or, better yet, “Are you reliable enough?” Your answer will tell how much you care about the concept of complete reliability.

Monday, 28 May 2012 17:46 - Capacity Assurance Marketplace

Mon, 28 May 2012 23:46:12 +0100

Explosion-Proof Linear Transducer

Balluff’s Micropulse TA12 is a non-contact linear position sensor with a compact, explosion-proof housing. It is specifically designed for continuous feedback on hydraulically and pneumatically actuated valves for oil and gas refining, storage, transport and handling. The transducer now has a IECEx hazardous-area approval rating, in addition to existing ATEX and North American approvals, expanding its acceptability for use in applications where hazardous gases and/or dusts are present.

Balluff, Inc.
Florence, KY

For more info, enter 30 at www.MT-freeinfo.com

Energy-Efficient Progressing Cavity Pumps

Allweiler All-Optiflow® progressing cavity pumps from Colfax offer up to twice the flow of standard pumps for applications up to 6 bar (87 PSI). Capable of moving any type of liquid, including fibrous and solid materials, they’re well suited to waste, wastewater-treatment and paper-manufacturing applications. According to the company, the pumps feature high power density that helps reduce energy consumption by up to 15%, when compared to standard progressive cavity pumps.

Colfax Fluid Handling
A business of Colfax Corp.
Monroe, NC

For more info, enter 31 at www.MT-freeinfo.com

Convert To Oil-Free Compressed Air

BOGE notes that its BC line of converter products offers new possibilities for pro-ducing environmentally friendly compressed air according to quality Class 0 (ISO 8573-0). They incorporate an innovative catalyst system that splits long hydrocarbon chains of residual oil in compressed air into carbon dioxide and water. The technology circulates compressed air around a receiver containing granulated, catalyst material, simultaneously cracking oil droplets and oil vapors. This results in oil-free compressed air and ultra-clean condensate.

BOGE Americas, Inc.
Powder Springs, GA

For more info, enter 32 at www.MT-freeinfo.com

Intelligent And Portable Condition Monitoring

SCOUT, part of GE’s Bently Nevada product line, is an intelligent suite of portable vibration monitoring and analysis instruments suited for the oil, gas and power-gen industries. The series offers fully integrated, single-provider solutions that support all plant-condition monitoring needs, including dual- or four-channel measurement and dual-plane balancing. The instruments’ field-proven Ascent® software can be programmed with thousands of separate machine definitions covering a number of route choices.

GE Measurement & Control
A part of GE Oil & Gas
Minden, NV

For more info, enter 33 at www.MT-freeinfo.com

Easily Programmed Alarm Trip

Moore Industries’ STA Safety Trip Alarm provides more than a standard alarm trip, monitoring potentially hazardous events and initiating emergency shutdown procedures or alerting personnel of unsafe process conditions. The company says it performs some of the same functions as other safety PLCs, but is easier to program. Process alarm trips and analog outputs are user-configurable via front-panel push buttons. Configurations can be downloaded to multiple STA units with free software.

Moore Industries-International, Inc.
North Hills, CA

For more info, enter 34 at www.MT-freeinfo.com

Surge Protection For AC Mains And Branches

MTL’s ZoneMaster PRO Type 1 allows users to install UL1449 3rd Edition-listed premium surge protection before or after the main building disconnect. Listed at 20kA in level, it can be installed in UL96A-certified lighting-protection systems. Its versatility makes it appropriate for switchgear, distribution and branch panels in a range of applications. Featuring replaceable, bolt-in modules, the product offers enhanced redundancy, thermal and short-circuit fusing and low let-through with high current impulses.

MTL Instruments
A business unit of Cooper Crouse-Hinds
Houston, TX

For more info, enter 35 at www.MT-freeinfo.com

Next-Generation Motor Analyzers

According to SKF, its Static Motor Analyzer – Baker DX models perform motor and generator analysis faster and more accurately than previous-generation surge test analyzers. They now include low-voltage inductance, impedance, phase angle and capacitance, coil and DC step voltage tests in a smaller, lighter-weight portable unit. Like their predecessors, the analyzers also conduct winding resistance, megohm, DC HiPot, surge tests and DC bar-to-bar armature tests. All units come with a touch-screen graphical user interface and can be ordered in an array of configurations.

SKF CMC-Fort Collins
Part of the SKF Group
Fort Collins, CO

For more info, enter 36 at www.MT-freeinfo.com

Smart Shop-Floor Management Of Consumable And Returnable Items

SupplyPro’s SmartDrawer™ has introduced the concept of individual compartment control for shop-floor cabinets at the point of use. This versatile, plug-&-go solution allows users to choose the best level of access control and accountability for each application. SmartDrawer lids can be set to provide Absolute Control® for single-item dispense and return, or part-number-level control for higher-density management. Available for new shop-floor cabinets or as a retrofit for existing cabinets, drawer by drawer, it can be used as a stand-alone unit, or combined with other SupplyPro devices. SmartDrawer comes with access to the manufacturer’s SupplyPort data-management offering, as well as with full implementation and on-call support services.

SupplyPro
San Diego, CA

For more info, enter 37 at www.MT-freeinfo.com

Monday, 28 May 2012 17:45 - Harness Valuable Knowledge Before It Leaves The Organization

Mon, 28 May 2012 23:45:34 +0100

Many companies struggle with the loss of experienced staff leaving the organization. Just as challenging—if not more so—is the loss of valuable plant-specific knowledge that these individuals carry with them when they go out the door.

Monday, 28 May 2012 17:44 - Technology Showcase: Information Technology

Mon, 28 May 2012 23:44:54 +0100

Web-Based, Full-Featured SaaS CMMS

Mapcon’s On-Demand™ uses SaaS (software-as-a-service) technology to provide comprehensive maintenance management, including work orders and preventive maintenance scheduling, at a lower cost than similar software applications. The product’s Java Swing™ technology delivers a fast, comprehensive CMMS directly over the Web, eliminating any slowdown associated with browsers. The system can be easily set up by non-IT personnel with basic PC skills and includes free technical support. On-Demand offers all features of Mapcon’s Enterprise software, including mobile capabilities. Being Web-based, however, it can operate in several environments (Windows, Apple OSX, Linux), connect to various databases (Oracle, SQL Server, Interbase) and communicate with other software packages. Because the service is billed on a monthly basis, without an annual contact, users can upgrade or downgrade on the fly without penalties.

Mapcon Technologies, Inc.
Des Moines, IA

For more info, enter 05 at www.MT-freeinfo.com

Robust, Professional-Grade Tablet Computers

Panasonic’s Toughpad™ A1 is a professional-grade 10” Android™-powered tablet suited for mobile outdoor workers and where exposure to extreme environments is a possibility. Designed to meet many of the same durability standards as Panasonic’s Toughbook PC product line, this new device has MIL-STD-810G ratings for drops, as well as ingress protection ratings for resistance to dust and water. It’s also rated for use across a wide range of temperatures. Besides having access to the selection of existing Android Market™ apps, the product is supported by the Business AppPortal™, an enterprise-focused app store offering market-specific solutions and applications addressing broad enterprise concerns, including Mobile Device Management, security and virtualization. This secure, cloud-based user storefront lets IT Managers and developers store, download and test apps for their Toughpad devices. Panasonic will also offer private application stores within the Business AppPortal, which businesses can customize to meet their specific needs.

Panasonic Solutions Co.
A division of Panasonic Corp. of North America
Secaucus, NJ

For more info, enter 06 at www.MT-freeinfo.com

IOS Vibration Analysis App

The Mobius iVibe™ from the Mobius Institute is an application for Apple’s iPhone, iPad and iPod Touch that provides a virtual vibration analysis expert. While diagnosing machine faults, iVibe provides an easy way to look up machine fault conditions based on spectrum symptoms and machine types. The application provides sample spectra, explanations of faults and explanations of how to diagnose fault conditions. Users can select from a list of symptoms, machine types and fault types before drilling down for more information on each topic. The application also includes a gallery with 80 spectral images. Upon seeing a spectrum, users can swipe up and down to see other similar spectra, or swipe left and right to see a page of details, diagnostic information and suggested additional tests to help confirm a diagnosis as correct. iVibe is available for purchase through Apple’s App Store.

Mobius Institute
Brentwood, TN

For more info, enter 07 at www.MT-freeinfo.com

Cross-Platform Mobile Support For IBM Maximo

Syclo’s SMART Mobile Suite For Maximo is now available for iPhone, iPad, Android smartphones and Android tablets. It’s been deployed for more than 400 IBM Maximo enterprise asset management software customers on Syclo’s Agentry Mobile Platform. According to the company, Syclo is the only vendor offering mobile solutions for IBM Maximo that work with all major devices, whether they’re online or not. Users get native applications without the need to maintain separate code sets for each device. Software designers get increased flexibility in configuring user interfaces to ensure that each application looks and behaves exactly as expected on each operating system. Syclo SMART Mobile Suite For Maximo works with IBM Maximo versions 4, 5, 6, 7 and 7.5.

Syclo, LLC
Hoffman Estates, IL

For more info, enter 08 at www.MT-freeinfo.com

This month's Technology Showcase is brought to you by:

Monday, 28 May 2012 17:44 - Motor Doc's Hot Topics: Voltage Unbalance Impact On Motors

Mon, 28 May 2012 23:44:22 +0100

Voltage unbalance and its most severe form—single phasing—cause up to 14% of motor failures [1]. It’s important to understand that maximum current unbalance isn’t defined in standards for motors in the field. Voltage unbalance, which has direct impact on the operating life and characteristics of an electric motor, is defined.

The National Electrical Manufacturers Association (NEMA) standard MG-1 defines the maximum voltage unbalance to be applied to an electric motor as 5%, and notes that a derating factor must be applied to a motor operating with a voltage unbalance.

Voltage Unbalance Derating Factor

Voltage unbalance is relatively simple to calculate. It requires measurement of the phase-to-phase voltage of the supply to a three-phase motor. The first step is to take all three measured voltages, add them together and divide by three. This will be your V_ave. Next, subtract the voltage furthest from the V_ave, change it to a positive value, then divide by V_ave and multiply by 100%.

For example, if you have V_a-b = 465V, V_a-c = 480V and V_b-c = 467V, then (465V + 480V + 467V)/3 = 471V_ave. Then ((480-471)/471) x 100% = 1.9%. Applied to the above chart, you would then multiply the horsepower or kilowatt rating of the motor times 0.95. In effect, a 10-hp motor would have to operate as a 9.5-hp motor.

If voltage unbalance is detected, you should identify the cause. If you see a current unbalance with a low-voltage unbalance, try rotating the phases, then recheck current. (Rotate phases by moving the lead from phase A to phase B, phase B to phase C and phase C to phase A. This doesn’t change the direction of rotation.) If, upon rechecking current, the unbalance moves, it’s motor-related. If the unbalance stays in the same location or disappears, it’s supply-related. MT

1. Cooper Bussman Corp., Motor Protection: Voltage Unbalance and Single-Phasing, 2003.

Dr. Howard Penrose is VP of Engineering and Reliability Services for Dreisilker, Webmaster of the IEEE Dielectrics and Electrical Insulation Society, and Director of Outreach of the Society for Maintenance & Reliability Professionals (SMRP).

For more info, enter 04 at www.MT-freeinfo.com

Monday, 28 May 2012 17:43 - The Reliability Files

Mon, 28 May 2012 23:43:49 +0100

This month's edition of the Reliability Files includes information from Fluke Corp. and Petro-Canada.

Monday, 28 May 2012 17:43 - For On The Floor: Salary Satisfaction?

Mon, 28 May 2012 23:43:04 +0100

GE’s Jack Welch is quoted as saying, “If you pick the right people and give them the opportunity to spread their wings and put compensation as a carrier behind it, you almost don’t have to manage them.” Most would agree, in principle if not always in practice. This month, our Reader Panelists report on how satisfied they are with their own compensation.

Monday, 28 May 2012 17:42 - Uptime: Learning From Sinking Ships And Aircraft Mishaps

Mon, 28 May 2012 23:42:23 +0100

“Human error” is an often-cited cause or contributing factor in accidents and failures. We routinely see this with our plant equipment. Without a structured process for identifying and quantifying the underlying human factors associated with specific incidents, however, eliminating human error can be quite challenging. Let’s look into a couple of historical examples for some valuable insight.

Monday, 28 May 2012 17:41 - Lubrication Checkup: A Motor Rebuild

Mon, 28 May 2012 23:41:42 +0100

Symptom:
“Dear Dr. Lube, we’ve received a motor [for rebuild] that runs in a hot environment. Its bearings are sealed and the motor is encased in a tube with no access to lubricate the bearings periodically. The OEM specifies SHC 100 bearing grease rated at 350 F. Koyo ball bearings come lubricated with Polyrex® EM grease, also rated at 350 F. Is one grease better than the other?”

Diagnosis:
Most motors are now sold with “sealed for life” bearings that require specialized grease to protect against high speeds, water washout, rust, corrosion and extreme temperatures while providing low noise properties.

Both greases mentioned are Mobil products. SHC 100, a synthetic PAO (polyalphaolefin) product with a lithium complex filler, is cherry-red in color. Polyrex® EM grease, a mineral-based product with a polyurea thickener, is blue. Both are NLGI number 2 greases, designed to operate in high-speed, severe and high-temperature applications. Mobil recommends both as premium electric-motor bearing greases.

In a direct comparison of typical grease properties, there’s little difference in their performance values. Polyrex® EM is a slightly higher viscosity at ISO 115, versus ISO 100 for the SHC 100, and has a slightly higher dropping-point temperature of 550 F versus 510 F for the SHC 100.

Results from a Koyo-bearing-provided Mobil ASTM D 3336 test (grease life in hours at 350 F) show the Polyrex® EM product as having over twice the high- temperature life expectancy of typical synthetic lithium complex greases.

Prescription:
When rebuilding motors, bearings are virtually always replaced. On the odd occasions when bearings are deemed suitable for reuse, it’s wise to flush and repack them with the original specified grease. (This is very important in such an application, as polyurea-based greases are incompatible with lithium-based products.)

When new bearings are used, the rebuilder has a choice of lubricants (as evidenced above). On paper, the Polyrex® EM product may look like the best candidate. That said, I urge you to contact ExxonMobil’s engineering department, describe the exact operating condition for the motor and let those lube experts prescribe which of their greases is best suited for your application. MT

Lube questions? Ask Dr. Lube, aka Ken Bannister, author of the book Lubrication for Industry and the Lubrication section of the 28th edition Machinery’s Handbook. He’s also a contributing editor for Maintenance Technology and Lubrication Management & Technology. E-mail: doctorlube@atpnetwork.com.

Monday, 28 May 2012 17:41 - My Take: Loving People Who Love Tools

Mon, 28 May 2012 23:41:03 +0100

A better title for this might have been, “Here’s To Some People Who Love People Who Love Tools,” but it would have been too long. To clarify, the reference is to YOU who love and count on state-of-the-art test and measurement (T&M) tools to keep your operations up and running and—as I came to realize recently—the people at Fluke who clearly understand and love YOU back. From what I see, there’s a lot of loving going on, in both directions.

Monday, 28 May 2012 17:40 - The Basics Of Roller Chain Sprockets

Mon, 28 May 2012 23:40:26 +0100

Installing new chain on old sprockets at your plant? Please say it ain’t so!

Monday, 28 May 2012 17:39 - “C”ing Successful Organizational Change

Mon, 28 May 2012 23:39:51 +0100

This article first ran in the October 1999 issue of MT. It’s presented as this month’s Anniversary feature because clarity, consensus and commitment never go out of style.

Monday, 28 May 2012 17:39 - Belt Drives: Investing In Inspection & Preventive Maintenance

Mon, 28 May 2012 23:39:12 +0100

No one can afford downtime or safety hazards that come with inadequate maintenance.

Monday, 28 May 2012 17:38 - At NSK, ‘Low Friction’ Equals Sustainability

Mon, 28 May 2012 23:38:32 +0100

The Japan-based bearing maker equates the low-friction, energy-saving qualities of its products with its aggressive campaign to cut waste and pollution. Its NSK Americas group is a strong part of the team.

Monday, 28 May 2012 17:37 - Planned Work Predominance: Contribution To The Bottom Line

Mon, 28 May 2012 23:37:25 +0100

The method presented here can help bring some much-needed clarity to your objectives.