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Asset Condition Management

Safe Electrical Work Planning & Plant Reliability

By Mike Doherty

It is agreed upon by most that the electrical system in any plant is a major factor in its reliability and therefore, profitability.

The Greatest Engineering Achievements of the 20th Century website at www.greatachievements.org states that "Electrification" is the single most important of the top 20 engineering achievements. The next 19 would not have been possible without electricity. The same holds true for electrification at your plant and its reliability. Without an outstanding electrical system that is maintained at the highest standards, reliability can and will suffer.

Applying Power Quality Measurements to Predictive Maintenance

You may already be using predictive maintenance (PdM) techniques on your motors and drives. But how often do you inspect the power to your equipment? By adding basic power quality measurements to production equipment maintenance procedures you can head off unexpected failures in both production equipment and your power system.

Asset Condition Management

Emerging Industrial Internet Technology Can Reduce Costs and Dangers in Steam Systems

Steam systems are vital to the smooth operation of so many manufacturing plants and other facilities. Numerous components are at work to ensure this smooth operation, but none more important than steam traps. Yet, despite their critical function, the majority of plants rely on time- and labor-intensive manual inspections. Yet, with the emergence of industrial Internet technology, steam traps make ideal candidates for automated sensing technology.

Leadership for Reliability

Operational Excellence: See the Flow of Value

by Joseph F Paris, Jr.

“Operational Excellence is when the efforts throughout the organization are in a state of alignment for achieving its strategies and where the corporate culture is committed to the continuous and deliberate improvement of company performance AND the circumstances of those who work there – to pursue ‘Operational Excellence by Design’ and not by coincidence.”

– Joseph F Paris Jr.,
Chairman, XONITEK Group of Companies

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Asset Condition Management

A Risk-Based Inspection Method for Flow Accelerated Corrosion Detection

by Thomas Godby

Leadership for Reliability

Ethics in Business…and What Do I Get?

In a society where the scale of values emphasizes individual issues first, then the person’s own family and ultimately society, I purposely begin this article with the provocation of the question above.

I believe we are all at a certain point on the scale, from one to 10, according to our moral development and the education we received. Frequently, we recognize the lack of ethics in others, but hardly recognize (sometimes even realize) our own lack of ethics. So, let’s start this article by answering the question.

by Luiz Alberto Verri

Asset Condition Management

Establishing Ultrasound Testing as a CBM Pillar Part 2

By Allan Rienstra and Thomas Murphy

"There's lots of talk about the benefits of implementing CBM and the positive impact that condition monitoring technologies like ultrasound testing can have. It seems we all have a good grasp of what it is and why we need it. The ultimate challenge is to move from inception to launch stage. Show me HOW TO DO IT."

Asset Condition Management

Leadership Q&A - Tim Rohrer of Exiscan

Terrence O'Hanlon, Publisher at Uptime magazine recently caught up with entrepreneur and innovator Tim Rohrer of Exiscan for a discussion on a new line of Infrared Viewing Windows.

Get the Bugs Out With the Uptime Elements
Work Execution Management

Get the Bugs Out With the Uptime Elements

Pop Quiz...

In the next 10 seconds, close your eyes and recite your maintenance department’s mission statement. Ready ... 3-2-1 ...

Go!!!

Probably 99 percent of you sat in complete and utter silence during those 10 seconds. But before you go off feeling guilty about being a subpar employee, you should really think about just what makes your mission statement so unmemorable. If one had to guess, more than likely it is too long and filled with vague buzzwords that make absolutely zero impact in how you approach your work.

At this point, you are probably thinking, “Okay, tell me what is the perfect mission statement for a maintenance department.” Well, since you asked nicely, here it is ...

Leadership for Reliability

Blame Complacent Engineers for Bad Management Decisions

Author's Note: While I'm solely responsible for this article, I am also entirely indebted to a process hazard analysis and loss control engineer (PHA/LCE) at a major refinery. In his contributed material, he is not disclosing anything of a proprietary nature. Still, it's a sign of the times that he has to remain anonymous. Perhaps it's because his expressions contain a measure of mild irony as he invades the comfort zone of equipment reliability engineers (REs). He quite obviously takes issue with their custom of limiting their work to mere analysis and recommendations. The REs, he notes, then consider their job done and let managers make decisions, some right and some wrong.

Removing Barriers to Reliability

Effective planning and scheduling are foundational elements for successful work management.

Well-defined and implemented planning and scheduling processes ensure that a plant's most important work will be done safely, efficiently and at the right time. Duke Energy professionals work diligently at improving their Midwest and Carolinas fleet's work processes through a Barrier Process. Work exceeding Estimated vs. Actual Hours targets is flagged, categorized and documented by technicians in the CMMS. These exceptions are reviewed weekly at a Barrier Meeting and assigned to plant personnel responsible for removing identified barriers. Barriers such as incomplete planning, incorrect parts, poor communication or coordination, scope creep, etc., result in unsafe situations, a frustrated workforce, plus a 10 - 20% productivity loss. With a clear focus on safety and asset reliability, Duke's planning and scheduling processes are sustainable and continuously improving because the Barrier Process energizes the Plan-Do-Check-Act cycle for reliability.

The Effects of Maintenance on Reliability

Publisher's Note: I will caution you that a) Bill Brinkley comes from the commercial Aviation industry where reliability is not optional and b) he pulls no punches when speaking to industrial maintenance professionals. I an interested in hearing what you can take away from this paper that was presented at IMC-2007. You can email me your comments or you can post them here.

In an airline environment, maintenance is king. An aircraft receives about 17 man-hours of maintenance for every flight hour. That may seem excessive - unless you are the one riding in that aircraft. So - the question is, do aircraft really break all that often and do they need that much maintenance? Are they that unreliable? The answer, of course, is no.

Aircraft are designed to be reliable, so why perform all that maintenance? Over ninety percent of the maintenance performed on an aircraft is preventive or servicing in nature. Preventive maintenance is done to maximize availability of the aircraft for operational service and minimize the number of failures occurring at inconvenient times or places.

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