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<strong>AMMJ</strong><br />
Contents<br />
<strong>July</strong> 2011 Issue Vol 24 No 3<br />
Asset Management and Maintenance Journal<br />
6<br />
A Guide to Increasing Productivity of the<br />
Maintenance Department<br />
An approach to a higher level strategic planning process<br />
that includes the grass-roots motivation and performance<br />
evaluation of individuals. Plus a checklist of productivity<br />
improvement methods.<br />
30<br />
Maintenance Decision Project<br />
At A Chemical Plant<br />
Investigates the use of a Maintenance<br />
Decision Support tool and how it may<br />
be used to improve reliability decisions<br />
based upon failure prediction.<br />
8<br />
12<br />
18<br />
Improving SCADA Operations Using<br />
Wireless Instrumentation<br />
As the use of wireless instrumentation<br />
networks increase, users will be faced<br />
with challenges to ensure the reliability<br />
& tight integration with existing<br />
infrastructure.<br />
Lubrication Reliability<br />
Human Memory is no match for computerisation when<br />
it comes to managing, performing and monitoring<br />
lubrication. But is even a CMMS good enough to manage<br />
the huge number of lubrication points in your plant?<br />
Maintenance Planning Is<br />
Too Hard In My Workplace<br />
Hey stop the excuses. The<br />
reasons why you should be<br />
motivated to move towards world class maintenance<br />
planning. Where are you now and moving forward.<br />
37<br />
38<br />
45<br />
46<br />
Simple Solutions To Big Problems<br />
Most organizations are looking for the “Silver Bullet”, or<br />
a Simple Solution to increase reliability but there is none.<br />
Let’s get back to the basics which will make a large impact<br />
on Reliability.<br />
Remaining Strength Prediction<br />
For Corroded Steel Plates<br />
Many steel bridge infrastructures of the world are getting<br />
old and hence subjected to corrosion wastage, etc.<br />
Are they safe to use?<br />
Spares Criticality Has Many Dimensions<br />
Most maintenance groups struggle with the issue of spare<br />
parts criticality. Is spare parts criticality a multi-dimensional<br />
issue?<br />
Total Productive Maintenance 20 Years On<br />
It is 20 years since TPM made its debut in the UK and this<br />
article takes the opportunity to look back at the original<br />
introduction of TPM and assess how it has progressed.<br />
21<br />
How long Should A Bearing Last<br />
What bearing life does your machine need?<br />
The short and long life needs of bearings in<br />
your plant.<br />
48<br />
Maintenance Books<br />
The latest Maintenance,<br />
Reliability and Asset<br />
Management Books<br />
22<br />
Condition Monitoring<br />
Equipment and Services<br />
The 2011 listing of providers of inspection and condition<br />
monitoring equipment and condition monitoring Services.<br />
54<br />
59<br />
60<br />
Maintenance News<br />
<strong>AMMJ</strong> Sponsors<br />
Maintenance Seminars<br />
Asset Management and Maintenance Journal<br />
ISSN 1835-789X (Print) ISSN 1835-7903 (Online)<br />
Published by:<br />
Engineering Information Transfer Pty Ltd<br />
Publisher and Managing Editor:<br />
Len Bradshaw<br />
Publishing Dates:<br />
Published in January, April, <strong>July</strong> and October.<br />
Material Submitted:<br />
Engineering Information Transfer Pty Ltd accept no<br />
responsibility for statements made or opinions expressed<br />
in articles, features, submitted advertising, advertising<br />
inserts and any other editorial contributions.<br />
See website for details of how to submit articles or news.<br />
Copyright:<br />
This publication is copyright. No part of it may<br />
be reproduced, stored in a retrieval system or<br />
transmitted in any form by any means, including<br />
electronic, mechanical, photocopying, recording or<br />
otherwise, without the prior written permission of the<br />
publisher.<br />
For all Enquiries Contact:<br />
Engineering Information Transfer Pty Ltd<br />
PO Box 703, Mornington, Victoria 3931, Australia<br />
Phone: (03) 5975 0083 Fax: (03) 5975 5735<br />
E-mail: mail@maintenancejournal.com<br />
Web Site: www.maintenancejournal.com<br />
COVER<br />
SHOT<br />
This issue’s cover<br />
shot is courtesy of<br />
Generation Systems<br />
and LUBE-It.<br />
See the article on<br />
Lubrication Reliability<br />
at Page 12.<br />
To Subscribe to the <strong>AMMJ</strong> go to www.maintenancejournal.com to download the SUBSCRIPTION FORM. Annual Subscription is from $80.
A Guide To Increased Productivity Of The<br />
Maintenance Department<br />
David Berger david@wmc.on.ca (Canada)<br />
(First Published in M&E Feb 2011)<br />
The role of leadership is to provide a<br />
strategic vision, with clear expectations<br />
for achieving it. The following steps<br />
describe a programmatic approach<br />
to bridging the higher level strategic<br />
planning process, with the grass-roots<br />
motivation and performance evaluation<br />
of individuals in light of the vision:<br />
Set performance targets for the<br />
department<br />
The first step is for Maintenance to partner<br />
with Operations and go through the strategic<br />
planning process, setting goals and objectives<br />
for the long term. Then, establish measures or<br />
indices that will reflect the level of performance<br />
regarding each goal and objective. The current<br />
value of each measure is then determined.<br />
Targets must be set which exhibit a graduated<br />
improvement over the long term. Take care to<br />
obtain ideas and commitment from all levels,<br />
from shopfloor to management, in Maintenance<br />
and Operations. Performance will be judged<br />
based on how aggressive the targets are, and<br />
how well the targets are met.<br />
Prepare action plan to meet targets<br />
To prevent targets from becoming simply<br />
numbers pulled out of the air, action items are<br />
created in light of strategic goals and objectives.<br />
The action plan describes how targets will be<br />
met. For example, if one target for this year<br />
is to reduce downtime by 2%, action items<br />
include setting up a more comprehensive PM<br />
program, initiating a training program for key<br />
equipment operators, and so on.<br />
Determine tasks, skills, and occupations<br />
required to implement the action plan<br />
The action plan may change the quantity and<br />
type of maintenance work that is required,<br />
and thus demand different skill sets. As well,<br />
new skills may be required to maintain new<br />
or modified equipment. Therefore, it may be<br />
beneficial to take an inventory of all the tasks<br />
that are currently done and will be done by the<br />
maintenance department. Then, classify each<br />
task as to skills required to perform the task,<br />
and the level of difficulty. Finally regroup the<br />
tasks into logical jobs and occupations. This<br />
exercise should be done jointly by workers and<br />
management, to achieve a buy-in at all levels.<br />
Establish quality & performance standards<br />
For each task defined above, quality standards<br />
must be set. The subjective nature of responses<br />
to questions such as ‘How clean is clean?’ can<br />
make this step difficult, but certainly possible.<br />
Where applicable, time standards should then<br />
be established.<br />
Measure performance using your CMMS<br />
Once tasks are defined and standards established, a CMMS can<br />
be used to help track how well individuals, groups of individuals,<br />
and the whole department are meeting those standards.<br />
FINDING AND QUANTIFYING PRODUCTIVITY IMPROVEMENT<br />
OPPORTUNITIES<br />
Many managers have asked me over the years for a simple checklist<br />
to use when looking for productivity improvement opportunities or<br />
when preparing a cost/benefit analysis. The following are some<br />
sample measures that may be useful in identifying and quantifying<br />
cost, quality, and service improvement potential as a direct or<br />
indirect result of better maintenance practices.<br />
CHECKLIST OF PRODUCTIVITY IMPROVEMENT<br />
MEASURES<br />
1. Labour<br />
a) labour rate (pounds/hour)<br />
b) turnover (people/year)<br />
c) absenteeism (hours/year)<br />
d) lateness (hours/year)<br />
e) utilisation (productive vs<br />
idle time)<br />
f) % time spent on non-value<br />
added activities (eg, material<br />
handling, excessive approvals)<br />
g) training cost/employee<br />
h) efficiency (variance to<br />
standard time)<br />
i) indirect or support hours (eg,<br />
clerical)/direct labour hours<br />
j) strike activity (dollar losses<br />
due to strikes)<br />
k) number and impact of<br />
improvement suggestions<br />
(ie, points to employee morale)<br />
2. Material<br />
2.1 Quality Problems due to<br />
Poor Maintenance<br />
a) scrap (can be sold)<br />
b) waste (no resale value)<br />
c) re-feed (item put back through<br />
process)<br />
d) re-work (item repaired off-line)<br />
e) give-away (revenue leakage)<br />
f) yield (% finished product<br />
that can be sold for premium<br />
pounds)<br />
g) shrinkage (eg. product sold<br />
by weight dries out during<br />
process)<br />
h) gain (eg. product sold by<br />
weight absorbs water during<br />
process)<br />
i) losses (eg. fraud, pilferage)<br />
j) returns (customer brings<br />
product back for refund)<br />
k) repairs (customer brings<br />
product back for re-work)<br />
l) % defective (% off-spec at<br />
various stages of operation)<br />
m) quality measures (variances<br />
used to highlight extent of<br />
deviations from quality spec)<br />
2.2 Spare Parts<br />
a) inventory level<br />
b) inventory turns<br />
c) storage costs<br />
d) stockout % (service level)<br />
e) fulfilment response time<br />
2.3 Vendor Performance<br />
a) late shipments<br />
b) damaged goods<br />
c) overshipments<br />
d) delays<br />
e) back orders<br />
f) wrong orders<br />
g) expediting cost<br />
3. Capital<br />
a) asset availability<br />
b) utilisation<br />
c) performance<br />
d) reliability<br />
e) quality of output<br />
(see #2 above)<br />
f) total cost of ownership<br />
4. Facilities<br />
a) maintenance cost/sq m<br />
b) capacity utilisation<br />
5. Energy<br />
a) total energy consumption<br />
b) peak consumption<br />
c) efficiency<br />
d) cost/unit<br />
Vol 24 No 3
info@infratherm.com.au<br />
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• 2 year warranty.<br />
NEC-AVIO offer outstanding quality and excellent performance at a value price.<br />
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Improving SCADA Operations Using<br />
Wireless Instrumentation Hany Fouda Control Microsystems (Canada)<br />
salessupport@controlmicrosystems.com<br />
Introduction<br />
Integrating wireless instrumentation with SCADA systems can drive operational efficiency and reduce deployment<br />
costs. The use of wireless instruments in pipelines and gas production operations has been gaining momentum<br />
over the past few years. Driven by cost cutting measures and the need to gain more operational visibility to meet<br />
regulatory requirements, wireless instruments eliminate expensive trenching and cabling while providing access to<br />
hard-to-reach areas using self-contained, battery-powered instruments.<br />
However, SCADA engineers and operators are facing the challenge of integrating wireless instrumentation networks<br />
with other communication infrastructure available in the field. Managing and debugging dispersed wireless networks<br />
presents a new level of complexity to field operators that could deter them from adopting wireless instrumentation<br />
despite the exceptional savings.<br />
The Evolution of Wireless<br />
Since Guglielmo Marconi sent the first telegraph signal across the Atlantic,<br />
wireless became part of our everyday lives. However, the last ten years<br />
have seen a dramatic change not only in the radio technology but more<br />
importantly in how we use it as consumers and producers such as oil and<br />
gas professionals. Gas producers and pipeline companies have relied for<br />
many years on long range wireless technology to transmit and distribute<br />
critical operational data using a wide range of technologies, including<br />
satellite, VHF, UHF and license-free spread spectrum. As more consumers<br />
lined up to acquire the latest Smart Phones with embedded Wi-Fi, Bluetooth<br />
and broadband capabilities, the price of radio modules plummeted. This has<br />
made it easy on industrial vendors to integrate radio modules into a long list<br />
of devices and sensors.<br />
As a result, the O&G industry has seen an increase in wireless instrumentation,<br />
also broadly known as wireless sensor networks, offered from major process<br />
control and SCADA suppliers. Wireless became the holy grail of the industry with editors and pundits predicting<br />
double digit annual growth.<br />
The business case behind deploying wireless instrumentation is a compelling one. By eliminating cabling and<br />
trenching, you can dramatically reduce the cost of deployment by as much as 70%. Since wireless instrumentation<br />
is battery powered, they are much easier to deploy in the field relative to their conventional counterparts. Wired<br />
systems can take days or weeks to be properly installed. Wireless instruments require only the sensor to be installed<br />
in the process, saving hours or days and valuable resources. Other instruments can be added as needed.<br />
Safety and compliance with environmental requirements are major driving factors. In gas production, during the<br />
initial flowback period, using wireless pressure sensors reduces the risk to personnel who would otherwise need to<br />
be in close proximity to a volatile and toxic well in order to read manual pressure gauges and to report on production<br />
readiness. During the flowback period before a wired solution can be installed, wireless pressure sensors put the<br />
well analyst in touch with the well enabling remote trending and analysis. EPA regulations in many regions require<br />
the use of a Vapour Recovery Unit (VRU) to burn off residual gases from separators & condensate tanks. An easy<br />
to install wireless temperature sensor can monitor the VRU & report an alarm condition if the flame goes out.<br />
Vol 24 No 3
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<strong>AMMJ</strong><br />
SCADA With Wireless Instrumentation 10<br />
Wireless Instrumentation is a Different Game<br />
So if the business case is that strong and the return on investment is solid, why are some still reluctant to deploy<br />
wireless instrumentation in their facilities? There are three main reasons:<br />
1. Reliability<br />
In industrial applications, reliability is a major concern. Wireless instrumentation must be as reliable as conventional<br />
wired units. Even in simple applications like remote monitoring, users come to expect a certain level of reliability<br />
and network availability.<br />
For example, the controls and communications for a<br />
wastewater pump station, often located far from the central<br />
control room, have to be reliable. If something goes wrong,<br />
maintenance people have to be dispatched immediately.<br />
South East Water Company in Melbourne, Australia,<br />
had that problem. Their dual submersible pump control,<br />
(Figure 1) required the local controller to cycle between two<br />
pumps, ensuring that both pumps were used approximately<br />
equally.<br />
The local controller also had to report critical system data,<br />
such as flow totals and pump running times to the central<br />
SCADA system. Grundy’s Electrics, a systems integrator<br />
in Melbourne, installed Control Microsystems SCADAPack<br />
controllers, local display panels, and DNP3 optimized radios<br />
at each pump station.<br />
Wired systems are much easier to diagnose and trace<br />
because the medium, the wire, is physically there or could<br />
be dug out. Wireless, on the other hand, uses the invisible<br />
free space as a medium. Radio signals are subject to free<br />
space attenuation, where the signal loses strength at a rate<br />
proportional to the square of the distance travelled. Radio<br />
signals are subject to reflection as a result of structure, trees,<br />
water bodies and buildings. Furthermore, interference from<br />
near-by wireless systems such as cell towers adds more<br />
challenges.<br />
RF design is getting better in addressing many of these<br />
issues. By designing highly sensitive radio receivers, using<br />
the transmit power more efficiently and high gain antennas,<br />
engineers were able to establish highly reliable RF point-tomultipoint<br />
links.<br />
Figure 1: Remote wastewater pump stations must have<br />
reliable controls & communications. South East Water Company<br />
in Melbourne uses SCADAPack controllers and wireless<br />
communications.<br />
2. Adaptability<br />
Wireless instrumentation networks are required to adapt to the existing environment. It is not practical to move a<br />
well head, a compressor, tank or a separator just to create a reliable wireless link. In long range SCADA networks,<br />
it would be much easier to locate a 30 foot tower in the field to allow for line-of-sight consideration. It might also<br />
be easier to increase the height of the tower to extend the range and avoid obstruction. Wireless instrumentation<br />
networks do not have that luxury. It is sometimes difficult to find a location for an access point or base radio<br />
that provides reliable communication with the wireless instruments. Relocating the access point or base radio to<br />
improve the RF link with one sensor could result in degrading the links with other sensors in the same network.<br />
Adaptability can be addressed by using lower frequency bands, such as the license-free 900 MHz, which tend<br />
to provide better coverage, longer range and better propagation characteristics allowing the signal to penetrate<br />
obstacles. Also, high gain external antennas that can be mounted as high as possible on a structure allow access<br />
to hard-to-reach sensors which could be located at the bottom of a tank. Improved receive sensitivity of radio<br />
modules also plays a crucial role in ensuring network adaptability to various industrial environments.<br />
For example, the Beypazari water system in Turkey is spread out over 270 square miles of mountainous terrain.<br />
They had problems with the distant locations of their alarm systems, so maintenance staff had to visit each pumping<br />
station three times a day to check on system operation. Because of the high cliffs, a wireless system appeared to<br />
be impractical.<br />
Beypazari installed Control Microsystems SCADAPack controllers at each of the nine remote sites. Wireless radios<br />
at each site and two wireless data concentrators—one on a hill overlooking the town—transmit critical data to the<br />
central SCADA/HIM system. The communication network is a mixture of 2.4 GHz radio modems and conventional<br />
UHF radio and line modems that are ideally suited to the mountainous locale in which they operate.<br />
Also, GSM (a digital mobile telephone standard) was implemented at the central location to provide Short Message<br />
Service (SMS) that sends alarms to operator cell phones.<br />
Vol 24 No 3
<strong>AMMJ</strong><br />
SCADA With Wireless Instrumentation 11<br />
3. Integration:<br />
Managing and debugging<br />
dispersed wireless networks<br />
presents a new level of<br />
complexity to field operators that<br />
could deter them from adopting<br />
wireless instrumentation despite<br />
the exceptional savings. The<br />
wireless network integration<br />
dilemma is more apparent in<br />
SCADA systems. Since wireless<br />
instrumentation networks are<br />
supposed to tie into the same<br />
SCADA infrastructure available<br />
at site to relay valuable operating<br />
data to the SCADA host, having<br />
the ability to manage the<br />
complete infrastructure as one<br />
network becomes essential.<br />
Despite the abundance of tools<br />
to capture, process and analyze<br />
data in the process control<br />
market, ensuring data integration<br />
is still a major problem. Some<br />
SCADA systems even have a<br />
separate historian module that<br />
must be purchased as an addon<br />
to handle the flood of data<br />
as a result of adding wireless<br />
instrumentation networks.<br />
A Coal Seam Gas (CSG) operation in Queensland, Australia, had that problem. CSG, abundant in Queensland,<br />
is the same as natural gas and is collected from more than 700 well sites scattered across the state. Parasyn<br />
Controls, based in Tingalpa, Queensland, is installing Control Microsystems’ SCADAPack controllers at each site<br />
(Figure 2) to collect data, provide local and remote control, report events, and communicate with central SCADA<br />
systems via radio links. Standardizing SCADA and wireless hardware from a single vendor made it simple to<br />
connect the remote sites to the central SCADA systems.<br />
Addressing the Wireless and Data Integration Challenges<br />
A new breed of advanced wireless instrumentation base station radios or gateways is now emerging in the<br />
marketplace. This new generation of gateways integrates both a wireless instrumentation base radio and a long<br />
range industrial radio in the same device.<br />
The integrated long range remote radio is configured as a remote device relaying information to a Master radio at<br />
the main SCADA center. The available two serial ports on the radio are configured to tunnel Modbus polling and<br />
diagnostic data simultaneously to the wireless instrumentation base radio. This allows operators to manage and<br />
diagnose the wireless instrumentation network through the existing long range SCADA infrastructure. Live data<br />
and status information for all field units are displayed in a separate view or integrated in the SCADA host.<br />
On the data integration front, modern SCADA host software offers a fully integrated environment that includes an<br />
integrated and scalable historian to handle more additional data without going through expensive and sometimes<br />
lengthy upgrades. Developing the SCADA screens based on templates allow engineers to add data points easily<br />
and rapidly in their systems.<br />
Conclusion<br />
Figure 2: Coal Seam Gas extraction in Queensland requires local control and<br />
monitoring at 700 wells scattered across the state. The local SCADAPack controllers and<br />
RTUs communicate via radio to centralized SCADA systems.<br />
As the adoption of wireless instrumentation networks increase, users will be faced with a number of challenges<br />
to ensure the reliability, adaptability and tight integration with their existing infrastructure. New RF and antenna<br />
designs help to address reliability and adaptability challenges. This leaves wireless and data integration with the<br />
existing SCADA infrastructure as one of the critical challenges to be resolved. Luckily, hybrid gateways, where<br />
sensor network base radio and long range radio are integrated, allow users to view, manage and diagnose their<br />
dispersed wireless systems from a single point. Similarly, advanced SCADA host software, with an integrated<br />
historian and rapid development environment using templates, can facilitate the integration of new data points<br />
generated by a growing network of wireless sensors.<br />
About the Author<br />
Hany Fouda is the VP of Marketing at Control Microsystems and is responsible for developing and executing global<br />
marketing strategies across the brand portfolio to further drive growth.<br />
Vol 24 No 3
Lubrication Reliability<br />
Human Memory vs<br />
Computerization<br />
Eric Rasmusson Generation Systems Inc<br />
www.GenerationSystems.com USA<br />
Lubrication reliability is an extremely important and complex operation not being adequately addressed by corporations<br />
world-wide. They give their focus to important operations such as accounts receivable, accounts payable, inventory<br />
control, CRM, and a host of other functions. In fact, no corporation would dream of running these complex activities<br />
without the advantages of software designed for the specific purpose. Yet these same organizations remain unaware<br />
of industrial lubrication being another complex activity requiring specialized software.<br />
Think about it for a moment. Most industrial plants consist of varied equipment numbering from the hundreds to the<br />
thousands. Each one of these equipment pieces typically includes multiple component parts requiring lubrication,<br />
such as a motor, drive-shaft and coupling. Multiple lube points per equipment result in thousands upon thousands<br />
of individual points to be serviced. Yet lubrication is even more detailed.<br />
Do The Maths<br />
Each individual lubrication point often requires multiple and differing activities to be performed, each at its own<br />
frequency. For example, proper care of just one lubrication point will require topping-off a reservoir each week,<br />
drawing a lab-sample every quarter, and draining and refilling with fresh fluid once a year.<br />
Several thousand lube-points, each with multiple tasks at varying frequencies - it easily works out to be hundreds<br />
of thousands of activities needing to be performed annually. This means, to ensure ongoing performance and<br />
reliability, many plants should be performing over 250,000 lubrication activities each year. In fact, a proactive and<br />
successful paper plant reports performing over 700,000 lubrication activities annually.<br />
Now consider the problem of so many lubrication points spread across several acres, numerous buildings, or multiple<br />
stories. This is even further complicated by an array of required lubricants, and the fact that distinct procedures are<br />
often required for each of the activities performed at a lubrication point.<br />
How is this daunting task being handled? Unfortunately, it’s often left, in full or part, to human memory.<br />
Common Wisdom<br />
Relying on human memory<br />
In some cases, lubrication maintenance personnel have been tending the equipment for years resulting in detailed<br />
understanding of the needs. Hopefully, these experienced personnel are never sick or on leave. Or worse yet, what<br />
are the consequences when just one resigns or retires? A missioncritical information asset is lost as they walk out<br />
the door. This starts a long and costly program of reassembling details and knowledge lost. Meanwhile, lacking<br />
experience, how does the new person on the block possibly lubricate without significant omission?<br />
Relying on spreadsheets<br />
Another widely used method is the computer spreadsheet. Typically this comprises a list of equipment along with<br />
numerous columns for lubrication specific data fields such as lubrication points and type, required lubricant, lubricant<br />
capacity and the frequencies at which to perform tasks. While able to convey the basics of what needs to be done<br />
and how often, such spreadsheets fail in knowing or communicating what specifically needs to be done and when.<br />
Most often lacking is the tracking of dates last completed—accurately entering this information for thousands of rows<br />
is an impossibly arduous task. Yet while updating spreadsheets proves difficult, accidental changes and deletions<br />
come all too easy. Knowledge of last-done is the key prerequisite to determining when individual tasks are “next<br />
due” without which the all-important questions remain unanswered.<br />
Which tasks are to be done this week?<br />
Which were missed last week?<br />
Also consider the hundreds of activities of longer duration, such as those performed every quarter, six-months, or<br />
once every year. It’s simply not possible to correctly remember when each activity was last completed. Once again<br />
the burden for proper lubrication is consigned to human memory.<br />
Relying on standard CMMS/EAM systems<br />
A third common approach is attempting to properly execute lubrication using the PM system of a CMMS or EAM<br />
product. Focused on CM & PM work-order management, these systems perform the role well, and most maintenance<br />
professionals are comfortable in their use.<br />
Vol 24 No 3
<strong>AMMJ</strong><br />
Lubrication Reliability 13<br />
Alas, comfort in a systems’ intended function is far from the best reason to apply it to other uses. Outside the<br />
CMMS are hundreds of products supporting additional reliability disciplines such as vibration, IR and others. Why?<br />
The work-order-centric design of a CMMS is incapable of supporting the unique data and activity requirements of<br />
these disciplines. Understanding lubrication reliability to be a unique discipline is the first step toward gaining its<br />
considerable benefits.<br />
As mentioned above, CM & PM work-orders typically number<br />
less than a few thousand annually, while annual lubrication<br />
activities can range up over 700,000. While the typical CMMS<br />
adeptly catalogs equipment at the nameplate level, these<br />
systems lack a clear approach for cataloging the multiple<br />
related lubrication points, let alone the multiple activities for<br />
each of these points. Also missing are the many data elements<br />
regularly found in the previously explained spreadsheets. The<br />
fact that these discipline-specific details are missing from the<br />
typical CMMS is the main reason such spreadsheets find<br />
common use.<br />
This lack of requisite details leads many into a minimalist,<br />
work-order level approach to lubrication. Simple monthly PMs<br />
are created for each equipment section or area, producing<br />
work orders with generic instructions such as “Lubricate<br />
stations 1 thru 8,” or “Check Levels in Bldg 12.”<br />
Striving for more detail, one plant of an integrated forest products company was required by corporate to use one<br />
of the large Enterprise Asset Management systems (EAM) to manage its lubrication program. The plant’s reliability<br />
engineer invested months of effort on repetitive keyboard entry of lubrication details into long-text fields. Shortly<br />
thereafter, and much to his dismay, it was decided to switch more than 200 reservoirs to synthetic lubricants, leaving<br />
him to edit each individually. Furthermore, with his hands tied by data locked into non-actionable text-fields, he was<br />
forced to answer with a definitive “NO,” when the plant manager asked him if his time and effort had resulted in an<br />
accurate and consistent lubrication program.<br />
Signing the order was easy...<br />
Greg wondered why he had taken so long to get outside assistance. Perhaps it was the fact that<br />
Maintenance consultants seemed to have a bad reputation – “Borrow your watch to tell you the time – then<br />
sell you your watch”. Perhaps it was because they had a reputation for charging exorbitant fees. Perhaps<br />
there was a little bit of pride involved – “It is my job to make this plant safe, efficient and reliable, and I am<br />
going to do it – myself!”<br />
But finally he had to admit that the challenges he faced were too great for any one person to deal with on<br />
their own, and he had contacted Assetivity. It’s amazing how a series of equipment failures (including a<br />
catastrophic conveyor pulley shaft failure that had caused a major safety incident and significant downtime)<br />
can focus the mind, he thought, wryly.<br />
At the initial meeting with the senior Assetivity consultant, Greg had been impressed by the way in which<br />
his problems and issues had been listened to, considered, and absorbed. He had liked the way that, in the<br />
course of their discussion, they had together been able to give focus to the complex network of issues and<br />
opportunities that he faced, and put these in perspective. He been attracted to the down-to-earth and<br />
practical discussion regarding implementation issues. And he was impressed by the focus on developing<br />
and implementing solutions, rather than on selling specific products, tools or methodologies.<br />
It had become clear, in the course of their discussion, that there was an urgent need to “get back to the<br />
basics” – to ensure that the current Preventive Maintenance program was appropriate, and was being properly executed at shop floor level, and that failures<br />
were being prevented, and the causes of those failures eliminated. They had agreed that the first step was to conduct a quick diagnostic review, focusing on<br />
these areas, in order to develop a plan of action. Getting authorisation from the Plant Manager had been surprisingly easy, and Greg was signing the Purchase<br />
Order for this review now. So far, it had been smooth sailing, but Greg knew that the real challenges lay ahead. But, with the involvement of Assetivity, he had<br />
confidence that they were on the right track.<br />
More than availability and reliability...<br />
Perth, Brisbane, Melbourne<br />
Ph +61 8 9474 4044<br />
www.assetivity.com.au<br />
Asset Management Consultants<br />
Vol 24 No 3
<strong>AMMJ</strong><br />
Lubrication Reliability<br />
14<br />
Many CMMS products allow for inclusion of a list or block of items with a PM, which can be used to list the lubrication<br />
points for an equipment area. Sounds simple doesn’t it? Unfortunately, the actual complexities of lubrication cannot<br />
be overlooked.<br />
Lubrication points within any equipment area are not identical. One key differentiator is the variation of frequency.<br />
Examples of such variation include some points being done weekly or biweekly, others monthly, bimonthly, quarterly<br />
or annually. A single PM can’t address this fact, this results in multiple PMs being created, one per frequency,<br />
for each equipment area. Equally important variations include the lubricant required, number of lube fittings, and<br />
activity type (top-off, change-out, sample, etc.). Further variation comes when activities require specific step-bystep<br />
procedural instructions. With the CMMS offering no native support for lubrication, how is such information<br />
conveyed using a single PM? How many PMs are needed to convey a bare minimum of these compulsory details?<br />
Remember, give a CMMS more PMs and it will return the favor with increased work-orders and paperwork. More<br />
importantly, within these numerous work orders and pieces of paper, there is no opportunity to bring optimization<br />
and efficiency to lubrication.<br />
What’s done is done. Or is it? Mark a work order as completed and the entire block of lubrication points share<br />
the same status. A PM system unable to function below the work-order level can’t remember the relevant “ all<br />
outstanding lubrication points” that must somehow be remembered over subsequent weeks until completed. It’s not<br />
hard to see this problem compounding week after week.<br />
Yes, having a multitude of detail deficient lubrication PMs might look and feel good on the surface, but it veils reality<br />
with a false sense of security. Once again, details required for success are left to the imagination and memory of<br />
lubrication personal. With such reliance upon manual effort, paperwork and human memory, it’s no surprise a recent<br />
search across popular CMMS/EAM websites for the term “lubrication” returned zero pertinent results.<br />
Customizing CMMS/EAM systems<br />
The fourth and by far the most costly approach is customization of the CMMS / EAM product for lubrication. Gaining<br />
rudimentary lubrication capability consumes hundreds of man hours, with one organization reporting having spent<br />
nearly $1,000,000 USD to modify a large EAM system so that it was capable of lubrication-point level of functionality.<br />
Even if successful, such customizations prove difficult and expensive to update. Personnel doing the original work are<br />
often otherwise assigned or no longer part of the organization. With corporations working to eliminate maintenance<br />
of in-house legacy systems, why should lubrication be any different?<br />
Counting The Cost<br />
Regardless of perception, it’s not a case of just the tin man with an oil can. In today’s competitive environment,<br />
the good old “Oil is oil” mentality does not suffice. This results in lubrication points being consistently maintained<br />
incorrectly, or worse yet, missed entirely. Yet management often declares or assumes lubrication to be in good<br />
order. You don’t get immediate feed-back when a lube point is missed. Often times it takes months or even years<br />
until the feed-back manifests as costly equipment failure and unplanned down time.<br />
This points to why over 50% of all equipment failures are traced back to poor lubrication practices. Numerous longterm<br />
studies in Canada, Germany, Russia, United Kingdom, and the United States declare this fact in unison.<br />
So this begs the question, why are these four approaches to lubrication so often employed? Organizations tend<br />
toward these approaches over a true lubrication reliability program for any of the following reasons:<br />
1. Lubrication Reliability not being understood as its own discipline<br />
2. Intuitive unease as to the detail and volume of activities required<br />
3. Management failure to calculate the cost of poor lubrication practices<br />
4. Management failure to calculate the payoff of lubrication reliability<br />
5. Lack of awareness of effective alternatives<br />
What is the net result of relying primarily on human memory? It is significant cost and loss. This includes unplanned<br />
downtime, capital equipment replacement, poor use of human resources and environmental risk. This is in addition<br />
to poor production quality and excessive energy consumption.<br />
Gaining The Benefits<br />
Responsibilities become clear and known<br />
What are the features and benefits of a well designed lubrication reliability software solution? Headaches and<br />
complexities are resolved. Maintenance planners and reliability professionals gain time to focus on other important<br />
initiatives. Most importantly, all lubrication specific details are clearly presented to lubrication personnel, ensuring<br />
lubrication is done right. That means: The right lubricant is used in the right place, at the right time, using the right<br />
procedure. Abnormal machine conditions are also noted, recorded and tracked until these conditions improve.<br />
Other important capabilities include: consumption tracking and trending, shutdown / outage planning and display of<br />
lock-out / tag-out safety information.<br />
Vol 24 No 3
Adver.indd 2<br />
6/10/2011 4:57:13 PM<br />
<strong>AMMJ</strong><br />
Lubrication Reliability<br />
15<br />
A good system will include an automatic lube-point / lube-task based work release. Tasks are released individually,<br />
and only as needed, not as blocks of work. These lubrication work assignments are automatically pushed to those<br />
responsible via footstep efficient routes. This frees maintenance planners from the detail of lubrication so they<br />
can focus on PMs and corrective work. Such a lubrication reliability system will also provide automatic backlog<br />
management. Individual lube-tasks, if not complete, are automatically marked past-due and brought forward each<br />
week until they are done, with no user intervention required.<br />
Mobile computing for accuracy<br />
The best systems also provide for rugged handheld computers using Windows Mobile operating system. This<br />
brings a great deal of efficiency to the system, with information literally at the finger tips of the lubrication specialist.<br />
No paperwork and no clipboards. Fingertip data collection includes work accomplished, consumption volume, and<br />
equipment problems and issues, all with no keyboard data entry. Mobile routes will also include provisions for<br />
positive verification of tasks performed via Bar-Code or RFID, as desired.<br />
Safety, energy savings and oversight<br />
It’s the detailed management of lubrication which enables a system to provide a wide array of lubrication reliability<br />
benefits. Benefits such as safety requirements accurately and clearly presented, right at the lube-point. Gains<br />
in efficiency and elimination of backtracking by simple use of drag & drop to re-sequence tasks within a route.<br />
Significant simplification of lubrication consolidation thanks to the system’s exact knowledge of lube product<br />
usage. These lube-point details allow for the straightforward implementation of lubrication ODR (Operator Driven<br />
Reliability). In addition, there will be a procedure library which provides task specific work-steps and eliminates<br />
repetitive data-entry.<br />
Equally important is detailed history for each lube-point as well as lubrication specific reporting. This detailed history<br />
is required for KPI oversight as well as for process improvement and failure analysis. It also enables international<br />
standards and audit accountability. Lubrication specific reporting brings forth information at both detailed and<br />
management overview levels. Providing instant understanding of program status, reports will be in both tabular and<br />
graphical formats.<br />
Problem Solving Made Easy<br />
For defect elimination, incident management & process improvement<br />
Eliminate unnecessary failures by using a systematic approach to problem solving.<br />
Teach your personnel how to identify the “root cause” of problems.<br />
RCA Rt provides training and coaching programs<br />
to grow a culture of defect elimination<br />
and continuous improvement.<br />
IncreaseProductivity<br />
ReduceDowntime <br />
Increase<br />
Public Workshops<br />
Onsite Workshops<br />
Ongoing coaching<br />
Instruction for internal trainers<br />
RCA Rt facilitators are expert incident<br />
investigators available to lead your team onsite<br />
RCA Rt Software – www.rca2go.com<br />
Maps 5 Why, RCA, FMECA, 6 Sigma’s DMAIC,<br />
RCM & PMO<br />
Contact Us<br />
Melissa Cameron<br />
Tel:+ 61 (0) 3 9697 1100<br />
melissa.cameron@sirfrt.com.au<br />
www.rcart.com.au / www.rca2go.com
<strong>AMMJ</strong><br />
Lubrication Reliability 16<br />
An added bonus is energy management - experts having found improper lubrication to be a major contributor to<br />
industrial energy consumption. Applying the right lubricant in the right amount consistently reduces friction with the<br />
net result of using less energy. With proper lubrication practices they now report a 20% gain in energy efficiency.<br />
Reality And Results<br />
By addressing the number one cause of equipment failure, reactive maintenance work decreases and overall plant<br />
reliability increases. Plants gain a focused and efficient lubrication reliability program including footstep reducing<br />
lubrication routes. Each route directs personnel from point to point, showing needed information, including detailed<br />
procedures. This eliminates the need for numerous PMs and the ongoing array of printed work-orders. All of which<br />
result in an incredible increase in reliability and productivity.<br />
In short, a lubrication reliability software solution will do the following:<br />
• Reduce Costly Downtime and Failures<br />
• Maintain Mission-Critical Knowledge Assets<br />
• Mitigate Human Factors<br />
• Maximize Employee Effectiveness<br />
• Cut Soaring Energy Costs by up to 20%<br />
Best of all, any one of these will quickly save more than the costs of the lubrication reliability solution. With these<br />
benefits, and the rapid ROI, it is difficult to understand why corporations continue to ignore this profound opportunity<br />
for increased competitiveness and profit year after year.<br />
Top reasons for having a dedicated lubrication plan<br />
It is generally accepted in the lubrication community that 60% of all mechanical failures are due<br />
to inadequate or improper lubrication practices.<br />
-- Kenneth Bannister, Lubrication for industry<br />
Proactive maintenance has now received worldwide attention as the single most important<br />
means of achieving savings unsurpassed by conventional maintenance techniques. A proper<br />
lubrication plan is proactive maintenance.<br />
-- James C. Fitch. P.E.<br />
Over 50% of all bearings failures are due to inadequate lubrication practices.<br />
-- Society of Tribologists and Lubrication Engineers<br />
6-7% of the gross national product (240 billion) is required just to repair the damage caused by<br />
mechanical wear. Wear occurs as a result of poor lubrication practices.<br />
-- Massachusetts Institute of Technology<br />
Much of the maintenance in most plants is performed in accordance to guesswork based on an<br />
owners manual as opposed to the machine’s true condition and need.<br />
-- A Forbes Magazine study<br />
It is almost certain that equipment is either being over-lubricated or under lubricated, and with<br />
most sites, management doesn’t know which.<br />
-- Lubrication Engineer, UNOCAL Corp.<br />
A lubrication/contamination control program was implemented plant wide that reduced the cumulative<br />
frequency of all tribological failures (from wear & contamination) by 90%.<br />
-- Nippon Steel<br />
A study was done that concluded lubrication system cleanliness extended time between repairs<br />
by 20-50 times depending on level of cleanliness.<br />
-- The British Hydromechanics Research Assn.<br />
International Paper reported a 90% reduction in bearing failures in just six months after they implemented<br />
a lubrication/contamination control program in their Pine Bluff Paper Mill.<br />
-- International Paper Company<br />
Vol 24 No 3
Maintenance<br />
2011 Seminars<br />
Download the full seminar brochure from:<br />
http://maintenancejournal.com/MaintenanceBrochure2011.pdf<br />
Seminar 1<br />
(1 Day)<br />
The Why, What, How and Who<br />
Of Maintenance<br />
Maintenance Costs. What Maintenance Does Your<br />
Organisation Need. Deciding What Maintenance Can<br />
Be Applied To Your Assets. Planned Maintenance,<br />
Preventive, Predictive, and Proactive Maintenance.<br />
Maintenance People, Maintenance Skills & Structures.<br />
Seminar 2<br />
(1 Day)<br />
Maintenance Planning and<br />
Maintenance Management<br />
Maintenance Planning, Scheduling and Control,<br />
Maintenance Stores, Computerised Maintenance<br />
Management Systems, EAM’s and ERP’s, Maintenance<br />
History Collection, Using Maintenance Data. An Introduction<br />
To Maintenance Management and Asset Management.<br />
Who Should Attend:<br />
Tradespersons, Technicians,<br />
Planners, Schedulers,<br />
Maintenance Supervisors,<br />
Engineers, Managers and<br />
Operations Personnel.<br />
If your organisation is based<br />
in the Asia / Pacific Region we<br />
may be able to provide these<br />
Seminars in your organisation.<br />
Contact Len Bradshaw at<br />
mail@maintenancejournal.com<br />
Seminars 1 and 2 Presented By Len Bradshaw (Aust)<br />
Workshop<br />
(1 Day)<br />
Applying Best Practices to<br />
Maintenance Planning &<br />
Control<br />
Ricky Smith has worked in Maintenance for some of the Best companies in the World<br />
and also was a Maintenance Company Commander in Iraq and Kuwait. Lessons<br />
learned from this experience are identified and discussed in this Workshop.<br />
Developing Effective Work Procedures. The Roles of a Planner. Planning Proactive<br />
Work Process. Feedback on the Plan once it has been executed. Daily and Weekly<br />
Scheduling. What to do about a low wrench time. Maintenance Planning effect on<br />
Work Execution. Feedback to the planner and schedulers. Maintenance Metrics and<br />
much more.<br />
Venues<br />
Brisbane<br />
14 - 16 September 2011<br />
Melbourne<br />
19 - 21 September 2011<br />
Workshop Presented By Ricky Smith (USA)<br />
Organised By Engineering Information Transfer P/L and the Asset Management and Maintenance Journal
Maintenance Planning Is Too<br />
Hard In My Workplace<br />
Ricky Smith GP Allied USA<br />
“Maintenance planning is too hard in my workplace.” I have heard this stated hundreds of times, and<br />
in some ways I agree with it. If maintenance planning was easy, everyone would be World Class and<br />
wrench time would be above 55% in all organizations. However, less than 2% of companies can honestly<br />
say they are World Class – that’s a small club, wouldn’t you say?<br />
Identify Where You Are<br />
Let’s begin with a few questions so you can measure the effectiveness of your current maintenance planning<br />
function.<br />
1. Do you measure Mean Time Between Failures (MTBF)?<br />
2. Do you have a maintenance planner?<br />
3. Does your planner get involved in emergency or urgent work?<br />
4. Does your planner have repeatable and effective work procedures for all critical or repeatable work?<br />
Note: Repeatable and Effective Work Procedures have, at a minimum: Step by step repeatable instructions to<br />
ensure everyone conducts Preventive, Corrective, and Lubrication maintenance following the same process and<br />
procedures; parts are kitted or staged before the job is scheduled; coordination was defined in the work package;<br />
and Specifications and Standards are defined.<br />
5. Are the parts kitted or staged before the work can be moved to “Ready to Schedule” status?<br />
6. Is the backlog estimated in labor hours?<br />
7. Is the backlog broken down into categories by labor hours, “such as waiting on parts”, “waiting<br />
on approval”, and “Ready to Schedule”? There are other possible categories, but these examples<br />
should be enough to help you understand the concept.<br />
Note: 4-6 weeks calculated in labor hours is a typical backlog of a World Class Organization.<br />
Example: 10 maintenance technicians x 40 hours/week = 400 labor hours. This is one week of backlog.<br />
8. Do you know the actual wrench time of your maintenance crew? If so, is it above 55%?<br />
9. Are your emergency/urgent labor hours under 2%?<br />
Moving Forward<br />
How did you score on the questions above? The answers to these questions will help an organization identify the<br />
start of the path towards World Class Planning.<br />
Why should you be motivated to move to World Class Planning:<br />
There is no rushing around to help everyone and save the day almost every day. Wow, what a relaxing job… and<br />
it is when accomplished correctly.<br />
The most serious issue one will face when developing a maintenance planning strategy is changing the culture of<br />
maintenance technicians, maintenance supervisors, maintenance management, production, engineering, etc. If you<br />
try to improve planning, you must address the culture first or you will never succeed. This is done through education<br />
of what true planning really is.<br />
Let’s take a look at what Albert Einstein had to say about change:<br />
“The significant problems we face cannot be solved at the same level of thinking<br />
we were at when we created them.”<br />
The bottom line is that everyone must understand the value of maintenance planning and agree with the process.<br />
Like a wise maintenance manager at a World Class facility told me,<br />
“this isn’t about commitment, it is all about compliance.”<br />
Why Is Maintenance Planning Sometimes Not Effective?<br />
Most people, when not motivated or not led by a true leader, begin to stray like lost sheep. Leadership is the first<br />
place to begin the education of true maintenance planning and also the rest of a proactive process. All the pieces<br />
need to fit together in order to achieve success.<br />
Let’s look at the results of proactive maintenance planning:<br />
There are many measurements that should be taken and used to evaluate a maintenance planning strategy. If<br />
they do not synchronize with your overall maintenance process, you will not see the results you expect. Other<br />
measurements are an output of Maintenance Planning effectiveness or can cause maintenance planning to fail.<br />
Vol 24 No 3
<strong>AMMJ</strong><br />
Maintenance Planning Is Too Hard 19<br />
Listed below are some leading indicators for verifying maintenance planning effectiveness:<br />
- 100% PM Compliance using the 10% Rule on critical assets<br />
- Emergency labor hours are trending down and percent of Planned Work is trending up<br />
- Vendor Efficiency is above 99%<br />
Note: Vendor Efficiency is calculated as the percent of time parts are delivered on time x the percent of time parts are<br />
ordered the same day x the percent of the time the right part and correct amount of parts are delivered.<br />
- Stores Efficiency is above 98%<br />
- Stores Stock Outs are less than 2%<br />
- Most of the jobs that are planned come from Potential Failures<br />
Note: A Potential Failure is an identifiable physical condition that indicates a functional failure is imminent and is<br />
usually identified by a maintenance technician using Predictive or quantitative Preventive Maintenance.<br />
- Rework is less than 2%<br />
MTBF is one measurement<br />
of maintenance planning<br />
that should definitely be<br />
required as it is a key<br />
Lagging Indicator. I know<br />
you are thinking, “does<br />
effective planning really<br />
correlate with MTBF?”<br />
In the graph below Check<br />
out the correlation of the<br />
data from a World Class<br />
Maintenance Organization,<br />
which demonstrates it does<br />
correlate. Optimize the<br />
maintenance process and it<br />
will change your life.<br />
You may be asking yourself,<br />
“How did this company<br />
obtain this type of increase<br />
in MTBF in such a short period of time just by focusing on maintenance planning?”<br />
If someone tells you maintenance planning itself makes your equipment<br />
more reliable and you believe them, then I have some property in<br />
Antarctica I would like to sell you.<br />
Maintenance planning cannot be successful without:<br />
• Maintenance planners focusing most of their time and effort on<br />
planning jobs for the future, or Potential Failures<br />
• The right work being identified at the right time. Most work<br />
should come into maintenance planning from Preventive<br />
Maintenance(PM) and Condition Based Maintenance (CBM) Tasks:<br />
o Execution of PM Tasks (includes lubrication) – 15% of total work<br />
o Work coming from the PM inspections – 15% of total work<br />
o Execution of CBM Tasks – 15%<br />
o Work coming from CBM Task – 35%<br />
• Storeroom and Purchasing adhering to specific guiding principles that were defined as a team with<br />
maintenance management and maintenance planning.<br />
• The Maintenance Schedule adhering to the time estimates of the maintenance plan;<br />
• The maintenance crew following the maintenance plan, which includes repeatable procedures,<br />
specifications, parts, etc.;<br />
• Work Order Data being closed out accurately in the maintenance software so metrics and failure data can<br />
determine if you are headed in the right direction;<br />
• Reliability Engineering focusing on the reduction of failures through analysis and making recommendations<br />
for changes in the maintenance strategy for specific equipment;<br />
• Maintenance Supervisors handling emergency parts, etc. for emergency work;<br />
• Leading and Lagging Indicators being posted for all to see.<br />
Vol 24 No 3
<strong>AMMJ</strong><br />
Maintenance Planning Is Too Hard 20<br />
The Proactive Work Flow Strategy illustration demonstrates how all areas must work in harmony or maintenance<br />
planning will not be effective.<br />
If you want to know if your maintenance<br />
planning is effective, check out these<br />
two key points:<br />
1. Call your maintenance planner<br />
and tell him or her that you have a<br />
breakdown and need a part. If you<br />
hear the dial tone, then you have a true<br />
proactive maintenance planner.<br />
2. If you have Self-Induced Failures<br />
or Human-Induced Failures (which<br />
account for 70-80% of equipment<br />
failures) you surely do not have<br />
effective maintenance planning & it<br />
makes good maintenance planning<br />
impossible. You need to remove or<br />
reduce variation in your maintenance<br />
work.<br />
75% of Failures are Human-Induced Failures<br />
“Creates an environment that is not conducive for successful maintenance planning”<br />
The following actions will all result in a failure caused by the lack of a procedure or personnel not following the<br />
procedure:<br />
• Improperly greasing a motor<br />
• Not using a torque wrench by mechanics and electricians<br />
• Installing a new pump and not realigning the motor with a laser<br />
• Not changing the Zinc Anode on a water cooled heat exchanger with copper tubes,<br />
causing pitting in tubes and water intrusion in the oil<br />
What Is the answer?<br />
While working for Alumax Mt Holly, or Alcoa Mt Holly as it is called today, I learned what true planning was. This site<br />
was benchmarked by hundreds of companies from around the world, and most of them came away saying, “that is<br />
nice, but we do not perform planning or scheduling like they do. We are different.”<br />
Below is the planning and scheduling process that was designed in 1980 for Alumax Mt Holly, and no, your<br />
organization is not different.<br />
Alumax (Alcoa) Mt Holly - Proactive Workflow Model (1980)<br />
In today’s world, we<br />
should be able to take<br />
EVENT<br />
USUALLY OCCURRENCE<br />
maintenance planning<br />
PM WO<br />
PRODUCTION<br />
to a new level where<br />
INSPECTION<br />
WEEKLY<br />
PM<br />
RESULTS<br />
WORK<br />
LUBRICATION<br />
DAILY<br />
PERFORMANCE<br />
REQUEST<br />
more of the work is<br />
PREDICTIVE<br />
SCHEDULE<br />
EVALUATION<br />
identified earlier in the<br />
MATERIALS<br />
failure process so that<br />
PLANNING<br />
WAREHOUSE<br />
TOOLS<br />
maintenance planning<br />
PROBLEM<br />
has time to plan a job<br />
SOLVING<br />
TEAM<br />
PRODUCTION<br />
effectively.<br />
REQUESTED<br />
Our focus is on the<br />
early identification of<br />
a Potential Failure<br />
or defect and not to<br />
reach the point of<br />
functional failure. Early<br />
detection of a defect<br />
is key to successful<br />
maintenance planning<br />
and scheduling.<br />
WORK<br />
PERFORMANCE<br />
HISTORY<br />
WEEKLY<br />
DAILY<br />
SCHEDULE<br />
PRODUCTION<br />
CO-ORDINATION<br />
MEETING<br />
TIME<br />
WORK ORDER<br />
CORRECTIVE<br />
PREVENTIVE<br />
MODIFICATION<br />
RESULTS<br />
1. PERFORMANCE TO SPECIFICATION<br />
2. MAINTAIN CAPACITY<br />
3. CONTINUOUS IMPROVEMENT<br />
EMERGENCY<br />
WORK<br />
ORDER<br />
Vol 24 No 3
<strong>AMMJ</strong><br />
Maintenance Planning Is Too Hard 21<br />
As an example of Proactive Planning and Scheduling the diagrams below show Ultrasound identifying a problem<br />
early on the P-F Curve, which then provides plenty of time to plan the job effectively and schedule the repair or<br />
replacement with little or no interruption to operations or production.<br />
Ultrasound Detected A Defect<br />
Proactive Planning and<br />
Scheduling<br />
Ricky Smith will be joining Len Bradshaw in Australia for the 2011 Maintenance Seminars:<br />
Go to the following URL for more information: http://www.maintenancejournal.com/MaintenanceBrochure2011.pdf<br />
Contact Ricky if you are struggling with maintenance planning: rsmith@gpallied.com<br />
Technical Short Feature:<br />
How Long Should A Bearing Last<br />
The short answer:<br />
“At least as long as the desired machine life.”<br />
Design lives of bearings have always been quite conservative: the older “L10” life requirements assured that<br />
there was never a more than 10% chance of a bearing failing during it’s design life - and the average bearing<br />
should last 5 times longer. Bearing life has been extended greatly over the last several decades. SKF reinvests<br />
about 2% of it’s operating budget back into R&D each year to continually push the envelope of what’s possible<br />
with bearing life. We still fail bearings regularly in the lab to verify that our theories match reality.<br />
Let’s get back to design life: some machines don’t need so much. A table saw might see<br />
occasional use at home - an hour a week or so. That’s only 100 hours a year, so even<br />
a bearing with a 1,000 hour life would satisfy a 10 year warranty. What happens when<br />
I decide to use that saw industrially, say, in a shop running 24 hours a day, seven days<br />
a week? The life requirement changes - dramatically. That same saw now needs the<br />
bearing to last 24x7x365 or almost 9,000 hours a year. For most industrial customers,<br />
you probably want that saw to last at least 5 years, meaning the design life is now<br />
9,000 x 5 or 45,000 hours. You’re going to need a larger bearing in that saw to meet the<br />
design life requirement.<br />
Some machines have even longer life<br />
needs. A machine making newsprint paper<br />
for example, has over 400 bearings from<br />
beginning to end - and almost every one can potentially shut<br />
down production. The bearings are oversized, to give a 100,000 to<br />
200,000 hour life with only a 10% chance of failure.<br />
What bearing life does your machine need? Contact your local SKF<br />
Bearing Application Engineering Service - they’ll be glad to help.<br />
Content and pictures coutesy of SKF @ptitude Exchange<br />
Vol 24 No 3
Condition Monitoring Equipment<br />
Suppliers and Services<br />
The 2011 Listing of Condition Monitoring Equipment and Services was compiled by Len Bradshaw, June 2011.The data given is as<br />
received from the respondents. The <strong>AMMJ</strong> does not therefore accept any liability for actions taken as a result of information given in<br />
this survey.<br />
Alstom MSc<br />
info.msc@alstom.com<br />
www.alstommsc.com.au<br />
CM PRODUCTS<br />
Alstom MSc is a premium provider of machinery health monitoring<br />
solutions to industry. The unique benefit that we offer is an integrated<br />
package of leading technologies, expert consultancy skills, training and<br />
customer support. This means we can tailor solutions to meet the<br />
needs of our customers.<br />
When dealing with Alstom MSc, you can be assured we have the<br />
product range, technical know-how and resources to deliver and support<br />
a condition monitoring package that works for you.<br />
Our product range includes:<br />
PORTABLE VIBRATION MONITORING - The Emerson CSI range has<br />
a reputation second to none in portable vibration monitoring. Our range<br />
includes CSI 2130 data collectors and analysers and AMS Machinery<br />
Manager software, plus the training and customer support to ensure<br />
the best program performance. For smaller plants and smaller CM<br />
programs, we offer the VMI range of hand held vibration meters and<br />
analysers.<br />
ONLINE VIBRATION MONITORING - For critical plant applications,<br />
online monitoring provides the best protection against machinery failure.<br />
However, quality engineering and project execution is important for<br />
success. Alstom MSc has a very well equipped team of online system<br />
engineers, with comprehensive experience in mechanical applications<br />
and instrumentation. Our product range includes full turbine supervisory<br />
systems through to simple online devices for smaller machines.<br />
SENSORS - Our extensive range of CTC accelerometers, cables<br />
and mounting hardware for monitoring online or inaccessible plant<br />
includes the PRO line of 4-20mA sensors for simple online monitoring<br />
and proximity probes for turbo machinery. CTC offers an outstanding<br />
UNCONDITIONAL LIFETIME WARRANTY on all products.<br />
WIRELESS VIBRATION MONITORING - For many applications,<br />
such as remote machinery monitoring, the costs of wired monitoring<br />
systems can be prohibitive. Our latest wireless solutions from Emerson<br />
dramatically reduce these costs, while providing reliability, security and<br />
integration with control systems.<br />
IR THERMOGRAPHY - We provide low cost thermal imagers through<br />
to advanced portable and online cameras .<br />
LUBRICATION ANALYSIS PRODUCTS - We offer Emerson CSI<br />
oil analysers and laboratory data management software and UVLM<br />
greasing monitoring devices.<br />
MEASUREMENT AND TEST PRODUCTS - Our range includes shaft,<br />
pulley and roll laser alignment systems, ultrasonic thickness meters,<br />
strobes, tachometers and stainless steel shims.<br />
CM SERVICES<br />
Alstom MSc has a 20 strong technical team, with experienced condition<br />
monitoring technicians and engineers in every mainland state providing<br />
a variety of technical services.<br />
TRAINING - We partner with the globally recognized Vibration Institute<br />
to offer their certification program, as well as a range of courses on CM<br />
other technologies.<br />
CUSTOMER SUPPORT - Our entire range of products is backed up by<br />
our dedicated direct support team. All of our support team members are<br />
qualified and experienced CM practitioners.<br />
ROTOR DYNAMICS - Multichannel monitoring, troubleshooting and<br />
balancing on gas, steam, hydro and wind turbines.<br />
VIBRATION MONITORING - Routine vibration surveys, advanced<br />
troubleshooting and diagnostics.<br />
ALIGNMENT AND BALANCING - In-situ balancing, shaft alignment and<br />
pulley alignment.<br />
IR THERMOGRAPHY - Electrical, refractory and mechanical routine<br />
scanning and investigations.<br />
OIL ANALYSIS- Full range of laboratory tests for contamination<br />
detection, wear analysis and lubricant condition.<br />
CM PROGRAM ASSISTANCE - Database tailoring, mentoring and<br />
auditing.<br />
SYSTEM DESIGN COMMMISIONING - Online system commissioning,<br />
DCS integration and instrumentation testing.<br />
REMOTE MONITORING & DIAGNOSTIC CENTRE (RMDC)<br />
Alstom MSc can remotely monitor your critical machines from our<br />
RMDC in Melbourne.<br />
apt Group (of Companies)<br />
info@aptgroup.com.au<br />
www.aptgroup.com.au<br />
CM PRODUCTS<br />
Portable/On-line Products<br />
The apt Group (of Companies) sell products incorporating advanced<br />
techniques and fast resolve/prediction to failure for Mechanical &<br />
Electrical plant diagnostics.<br />
Products suit large and small industrial plants, production critical and<br />
less critical machines, operator and service provider applications.<br />
Equipment<br />
Agency agreements for Pruftechnik, EuroPulse, Guide, APIPro, AlltestPro,<br />
APT, amongst others.<br />
Machine/Bearing Monitoring: predictive trending tools, Data Loggers,<br />
FFT Analysers, Fixed Monitors & WEB based Surveillance – Vibration,<br />
Eccentricity, Acoustics, Ultrasonic, Temperature.<br />
Alignment/Laser Measurement: Shafts; Pulleys; Machines.<br />
Dynamic Balancing: Rotors/Fans.<br />
Battery Maintenance: Extend Life/Rejuvenate.<br />
Electric Motor Monitoring: detect & measure the severity of AC motor<br />
stator and rotor problems, DC motor field winding problems, power<br />
problems and cable issues.<br />
Motor Circuit Analysis (MCA): off-line static impedance based testing,<br />
assesses the condition of AC/DC motors, providing in-depth analysis<br />
of the motor circuits - turn-to-turn shorts, open turns/coils, reversed<br />
coils, coil-to-coil shorts, connection defects, air gap defects, rotor<br />
defects - broken bars, eccentricity and casting voids. Also, Electrical<br />
Signature Analysis (ESA) for complete on-line dynamic Motor/Power<br />
Diagnostics.<br />
Infrared Cameras: Predictive Maintenance; Research Development;<br />
Machine Vision; Surveillance.<br />
Software<br />
Asset Performance Tools: cost/risk evaluation.<br />
Asset Efficiency Optimization: data management, display/analysis.<br />
Knowledge Based: efficient diagnostics of machinery problems “rule<br />
based”; justification/explanation.<br />
Decision Support: facilitate reliability efforts, root cause failure analysis,<br />
cost calculation/tracking.<br />
Maintenance Management: resources, inspection/maintenance<br />
routines; interface condition monitoring, finance, production.<br />
CM SERVICES<br />
The apt Group (of Companies) is an Independent Engineering<br />
Consultancy – providing Condition Monitoring Services focusing on<br />
Plant Reliability.<br />
Contractual/one-off plant surveys, project engineering, advise in<br />
system/component selection/implementation.<br />
Highly qualified personnel, applying best practices, international<br />
standards and corrective recommendations.<br />
Vol 24 No 3
Vol 24 No 3<br />
<strong>AMMJ</strong><br />
23<br />
2011 CM Equipment and Services<br />
Mechanical Discipline<br />
Machinery Diagnostics; Vibration Analysis; Modeling; Alignment;<br />
Balancing; NDT; Oil Analysis.<br />
Electrical Discipline (LV & HV)<br />
Motor Management/Diagnostics, Thermal Imaging, Switchboard<br />
Inspections, Power Factor Correction/Condition Analysis.<br />
Substations, Transformers, Circuit Breakers, Busbars, DC Systems,<br />
Power Cable Testing & Diagnostics.<br />
Support Services<br />
Plant Surveys, Database Establishment/Management, Data Analysis,<br />
Training/Seminar Programs.<br />
On-site and remote data analysis/management services are available<br />
“around the clock”.<br />
The apt Group of companies, promote Precision Engineering /<br />
Maintenance practices. Both in-house personnel and world-renowned<br />
advisors are available to undertake site audits, review in-house<br />
processes and assist with change as needed.<br />
Aquip Systems<br />
sales@aquip.com.au<br />
www.aquip.com.au<br />
CM PRODUCTS<br />
PRÜFTECHNIK’s Condition Monitoring products include both online<br />
and offline formats. The OMNITREND PC platform is common to all<br />
systems, allowing you to create comprehensive databases and archives<br />
along with flexibility and reliability<br />
OFFLINE SYSTEMS: Data collectors and Analysers:<br />
VIBXPERT II: a high performance, full-feature 1 or 2 channel FFT data<br />
collector and signal analyzer for the monitoring & diagnosis of machine<br />
condition. Full VGA colour screen for immediate analysis. Optional<br />
features include Balancing and Orbits.<br />
VIBSCANNER: Expandable mid-range data collector for vibration data,<br />
temperature, speed and process parameters. Add-on modules available<br />
for Full Spectrum, Time Waveform, Balancing & Laser Alignment.<br />
VIBCODE: The breakthrough vibration transducer with automatic<br />
measurement point identification for all systems, guaranteeing accuracy,<br />
repeatability and measurement integrity.<br />
OFF-LINE: Machine protection and Vibration Analysis<br />
VIBNODE, VIBROWEB XP, VIBROWEB, VIBRONET SIGNAL<br />
MASTER : Intelligent machine monitoring systems that can perform<br />
measurements, evaluation, archiving & alarm warning. Very-fastmultiplexer<br />
systems are available with up to 120 measurement channels.<br />
The internal web server & email server within these systems provides<br />
convenient remote access from any PC.<br />
Prüftechnik Laser Alignment – 25 years of excellence from the<br />
Inventors and Market Leaders!<br />
Rotalign Ultra: The tool of choice for Service providers and OEMs,<br />
the Rotalign Ultra is now capable of performing Vibration Acceptance<br />
checks with the new VIBTOOL functionality. Measuring vibration levels<br />
to ISO 10816-3 standards, the VIBTOOL sends data to Rotalign Ultra via<br />
Bluetooth for storage along with Alignment data and report generation.<br />
Many new features are now available including ; flatness, positional<br />
displacement measurement, parallelism, and bore alignment.<br />
New Modular Systems: Because one size does not fit all!<br />
OPTALIGNsmart and SHAFTALIGN incorporate a range of Prüftechnik’s<br />
patented features as standard along with the latest technology in<br />
graphics and human interface. Systems are tailored to suit your needs<br />
by selecting only the features you require. If your needs change in the<br />
future and you wish to add-on, additional features are simply unlocked<br />
with a password – no time off-site!<br />
Training that really works.<br />
Don’t miss out. Book today.<br />
Motor Diagnostic<br />
Workshop<br />
by Bill Kruger of ALL-TEST TM<br />
EAST COAST AUSTRALIA 10–14 Oct 2011<br />
WEST COAST AUSTRALIA 17–21 Oct 2011<br />
Presenting Motor Circuit Analysis (off-line testing)<br />
& Electrical Signature Analysis (on-line testing).<br />
Learn:<br />
• how to improve motor system reliability and<br />
reduce energy costs.<br />
• motor theory and the latest techniques for testing<br />
motors – all sizes & types.<br />
• new software products and equipment from world<br />
renowned ALL-TEST Pro.<br />
For more information go to<br />
www.aptgroup.com.au<br />
or call 1300 700 002<br />
ALL-TEST PRO TM<br />
PREDICTIVE MAINTENANCE<br />
The only<br />
Complete System<br />
for motor diagnostics<br />
Online and Offline<br />
EASY & SAFE MOTOR TESTING – fast, accurate and non destructive<br />
PREDICTIVE MAINTENANCE – early detection and time to failure estimates<br />
STATOR FAULTS – turn, coil, phase, ground and connection faults<br />
ROTOR FAULTS – casting void, mechanical and rotor bar faults<br />
POWER QUALITY – transformer, VSD, harmonics and cable fault detection<br />
POWERFUL SOFTWARE – trending, analysing, writing reports and work orders<br />
ASSET MANAGEMENT – motor database and energy efficiency calculations<br />
COST EFFECTIVE – optimise motor availability and production<br />
QUALITY ASSURANCE – motor faults quantified and repairs assured<br />
LOCAL SUPPORT – training and technical backup<br />
GREAT DEALS TO BUY OR LEASE<br />
Risk Management<br />
Part of the apt Group<br />
Vol 24 No 3
Vol 24 No 3<br />
<strong>AMMJ</strong><br />
24<br />
2011 CM Equipment and Services<br />
CM SERVICES<br />
Aquip Systems provides expert ongoing condition monitoring services<br />
as well as ad-hoc machine diagnosis. We provide a range of training<br />
courses to suit all experience levels.<br />
Condition monitoring and laser shaft alignment courses focus on<br />
theoretical aspects and practical applications to suit the clients’ site<br />
requirements.<br />
We also operate the sole PRÜFTECHNIK certified service centre in<br />
Australia, and are fully equipped to carry out services, repairs and<br />
calibration checks on all PRÜFTECHNIK equipment.<br />
FLIR Systems<br />
Australia<br />
info@flir.com.au<br />
www.flir.com/thg<br />
CM PRODUCTS<br />
FLIR Systems is the world leader in infrared cameras, having the widest<br />
range and offering the highest standard of any supplier for predictive<br />
and preventative maintenance. The FLIR range includes:<br />
• The low cost, powerful little revolutionary FLIR i3, producing<br />
snapshots of temperature differences equal to 3,600 readouts from a<br />
single spotmeter with the i5 and i7 producing even more.<br />
• The ground-breaking FLIR E-Series extends performance and<br />
affordability with features like Bluetooth® and industry-first Wi-Fi<br />
connectivity, 3.5” touchscreen and iPhone/iPad App. Add to this<br />
MeterLink, the pioneering wireless connection from FLIR, that connects<br />
your infrared camera with your ClampMeter.<br />
• The FLIR T-Series also has MeterLink and offers an optimum mix of<br />
ergonomics and flexibility. The new T600-Series takes quality of image<br />
to a whole new level and has a long list of impressive features, including<br />
Wi-Fi connectivity, 4.3” touchscreen and iPhone/iPad App.<br />
• The brilliant FLIR P660, featuring a 640 x 480 uncooled<br />
microbolometer array with measurement and also possesses GPS.<br />
• The A-Series, which can be installed almost anywhere to monitor<br />
critical equipment and automation systems.<br />
• FLIR’s GF-Series optical gas detection cameras letting you find<br />
hydrocarbon, natural gas and SF6 leaks quickly, accurately and safely<br />
without shutting systems down for inspection.<br />
• A variety of software packages turning tools into solutions. All users<br />
of FLIR’s thermal imaging camera systems can work more efficiently<br />
and productively by utilising the most professional camera-software<br />
combinations.<br />
• Quality tested infrared windows<br />
CM SERVICES<br />
FLIR offers unsurpassed support in before and after sales service.<br />
This includes demonstrations and advice on the right camera for the<br />
application, training options, as well as rental systems and a dedicated<br />
service department.<br />
When you buy or rent an infrared camera from FLIR, it comes fully<br />
guaranteed, and now many FLIR cameras are eligible for coverage<br />
under FLIR’s industry-leading 2-year product and 10-year detector<br />
warranties*. ( * Terms and conditions apply )<br />
At FLIR we understand that turnaround times are critical, so we have<br />
an in-house, dedicated service department offering full service, repairs<br />
and re-calibration.<br />
FLIR Systems’ certified service centre is headed by its factory trained<br />
and experienced service manager.<br />
FLIR also provides various levels of infrared training, from half day<br />
introduction courses, onsite training through to FLIR’s ITC course.<br />
The Infrared Training Center (ITC) offers the world’s leading infrared<br />
training and thermographer certification programs.<br />
Fluke Australia<br />
sales@fluke.com.au<br />
www.fluke.com.au<br />
CM PRODUCTS<br />
Fluke’s high performance thermal imagers have never been this rugged,<br />
this reliable, and this easy to use until now! Fluke Thermal Imagers are<br />
the ultimate tool for troubleshooting and maintenance.<br />
Fluke, are never satisfied leaving the best tools in the hands of the elite.<br />
The introduction of their P3 Series handily delivers on the promise to<br />
offer the most tools for your money.<br />
Joining the prestigious Ti32 Industrial and TiR32 Building Thermal<br />
Imagers, the P3 range introduces the Ti27, TiR27, Ti29 and TiR29 to the<br />
family. Each of these imagers boasts Fluke’s renowned qualities for:<br />
Superior image quality<br />
Industry-leading thermal sensitivity and spatial resolution combined with<br />
a high definition display, creates the sharpest images in the industry.<br />
Torture tested<br />
Before a Fluke goes into your hands, we drop it from ours. Only Fluke<br />
thermal imagers are designed from the inside out to withstand a 2 metre<br />
drop.<br />
Patented Fluke IR-Fusion®<br />
(Picture-in-picture and auto blending) Precision visible and IR image<br />
alignment allows Fluke to offer the only on-camera blended infrared and<br />
visible image to better diagnose issues.<br />
Optional Wide-Angle Infrared and Telephoto lenses are available with<br />
Fluke thermal imagers. Not to mention all cameras include SmartView®<br />
software with FREE software upgrades for LIFE!<br />
Fluke redefines mechanical troubleshooting with a revolutionary product:<br />
The Fluke 810 Vibration Tester, the most advanced troubleshooting tool<br />
for mechanical maintenance teams who need an answer NOW! Control<br />
unplanned downtime, prevent recurring problems, set repair priorities<br />
and manage your resources with an entirely new approach to vibration<br />
testing.<br />
The Fluke 810 is designed specifically for maintenance professionals<br />
who need to troubleshoot mechanical problems and quickly understand<br />
the root cause of equipment condition.<br />
You take pride in your facility, your team, and your work. You do what it<br />
takes to keep things up and running, but sometimes there is not enough<br />
time or resources to keep up with the workload, let alone be proactive<br />
about mechanical maintenance. The Fluke 810 Vibration Tester puts<br />
you one step ahead by using a simple step-by-step process to report<br />
on machine faults the first time measurements are taken, without prior<br />
measurement history. The combination of diagnoses, severity and repair<br />
recommendations help you make informed maintenance decisions and<br />
address critical problems first.<br />
CM SERVICES<br />
Thermal Imaging and Vibration training courses run throughout the year<br />
by Fluke Australia.<br />
Infratherm<br />
info@infratherm.com.au<br />
CM PRODUCTS<br />
Infratherm is a premium supplier of Thermal Imaging Cameras and<br />
attendant Report and Analysis Software for Preventative Maintenance<br />
and Condition Monitoring applications.<br />
With over 22 years experience & continuous service in the Thermal<br />
Imaging Market, Infratherm can provide a range of services and<br />
applications support that has become the bench mark in the industry.<br />
Full maintenance and calibration services are provided along with<br />
accredited training programs in infrared technology.<br />
Infratherm offer equipment from the world’s leading manufacturers of<br />
thermal imaging equipment, primarily NEC-Avio and have been their<br />
Vol 24 No 3
Take a vibration<br />
expert along<br />
NEW Fluke 810 Vibration Tester:<br />
When you need an answer now…<br />
1<br />
Control unplanned downtime, prevent recurring problems, set repair<br />
priorities and manage your resources with an entirely new approach<br />
to vibration testing. The new Fluke 810 helps you locate and diagnose<br />
common mechanical problems and prioritise repair actions in three<br />
simple steps:<br />
1<br />
SETUP<br />
Vibration testing has never been easier.<br />
The 810 asks for basic machine information you already know. Its onboard Info<br />
feature gives you field tips for setting up and taking measurements like a pro.<br />
2<br />
2<br />
MEASURE<br />
Fluke 810 fits easily into your maintenance routine.<br />
Use it to quickly troubleshoot problems or monitor machine conditions.<br />
3<br />
DIAGNOSE<br />
No more guessing your machine’s condition.<br />
With the press of a button, the Fluke 810 identifies the root cause, its<br />
location, and how severe it is. Fix it right the first time.<br />
3<br />
The Fluke 810 is the most advanced troubleshooting tool for<br />
mechanical maintenance teams.<br />
See for yourself at www.fluke.com.au or<br />
call +61 2 8850 3333<br />
©2011 Fluke Corporation. Specifications are subject to change without notice.<br />
Fluke. Keeping your world<br />
up and running. ®
Vol 24 No 3<br />
<strong>AMMJ</strong><br />
26<br />
2011 CM Equipment and Services<br />
main distributor for 10 years.<br />
NEC-Avio’s Latest offerings are:<br />
• The F30 and G30 for the Electrician.<br />
• G100/120 for the CM/ PM market,<br />
• The H2640 & H2630 with 640 x 480 Arrays.<br />
• The work horses of the Industry in the form of the TH9100 and<br />
TVS 500/200 in 320 x 240 format<br />
All with State of the Art Features.<br />
Infratherm offers a well rounded range of Thermal Imaging Radiometers<br />
& Imagers but are not limited to a single supplier or brand name. Our<br />
focus is on customer needs and satisfaction and we back this up with<br />
the best service in the industry.<br />
In addition to Hand-Held units Infratherm also provide Process<br />
Monitoring Radiometers & Imagers in Modular form for OEMs or can<br />
set up & integrate cameras to suits the end users requirements.<br />
CM SERVICES<br />
Infratherm provide a range of Thermal Imaging Radiometric Cameras<br />
for Conditioning Monitoring and Preventative Maintenance Applications.<br />
Cameras are tailored to suit customer applications. e.g. jacketed /<br />
cooled; environmentally protected; customized etc.<br />
All cameras are supplied with Reporting and Analysis Software.<br />
Software ranges from Static Analysis & report generation with Real-<br />
Time Sequence Analysis to Real –Time monitoring with full data<br />
analysis capability. Infratherm also provide accredited training courses<br />
in Thermographic practices with emphasis on how to conduct Condition<br />
Monitoring inspections. As an independent supplier of thermal inspection<br />
equipment and training, the focus is on customer needs and support.<br />
Machinery Vibration Specialists<br />
Australia<br />
mvsaust@ozemail.com.au<br />
www.spminstrument.com.au<br />
CM OVERVIEW<br />
MVS Aust P/L is a specialist company supplying products, support<br />
services and technical training for the maintenance and repair of<br />
rotating machinery.<br />
CM PRODUCTS<br />
SPM Instrument - AB of Sweden:<br />
Originator of the “True Shock Pulse Method” for bearing measurement<br />
& analysis.<br />
Innovator of the NEW SPM HD for low speed (1 to 20,000 rpm) bearing<br />
measurements.<br />
BearingChecker --- Low cost, pocket, bearing measurement &<br />
evaluation instrument.<br />
VibChecker ---- Low cost, pocket, vibration instrument to ISO 10816<br />
with FFT spectrum.<br />
Leonova Infinity ---- 2-Channel Bearing/ Vibration Analyser with<br />
Balancing, Laser Shaft Alignment, Bump Tests, Orbit & Lubrication<br />
Analysis and Order Tracking and Phase Analysis.<br />
On-Line Machine Monitoring and Protection<br />
Machine Guard -- single/multi channel with relays, Modbus, 4-20mA.<br />
Intellinova --- Up to 32 Channels SPM HD, vibration, analogue in/out.<br />
Intellinova Compact --- Units with 6,12 &18 channels very cost effective.<br />
Uses SPM HD, vibration, analog in, 3G interface<br />
All designed to monitor complex machines such as container cranes,<br />
wind generators, rolling mills, paper machines, cement plant machinery<br />
and mining conveyor and crushing systems. Especially Ultra Low<br />
Speeds<br />
CEMB SpA - Italy<br />
Maintenance & Process Dynamic Balancing Machines.<br />
True “Hard Bearing “ force measuring machines, horizontal & vertical.<br />
Maintenance & Production for 10Kg to 50,000Kg.<br />
IRD Balancing LLC - USA<br />
Maintenance Dynamic Balancing Machines.<br />
“Soft Bearing” motion measuring machines, horizontal<br />
Transportable, from 10Kg to 200,000Kg.<br />
Lexseco--- Motor Core Loss Testers form 10 to 300KVA.<br />
Support Instruments.<br />
Rayhome Ltd.------ High quality pre-cut SS shims in packets of 10 or<br />
boxed kits.<br />
Hilger u. Kern GmbH ----- Laser Belt Tension Instrument & Leak<br />
Detectors.<br />
MVS SUPPORT SERVICES<br />
• Instrument and machine repair and calibration to NMI<br />
standards.<br />
• SPM CM Software installation and Commissioning<br />
• Monitor and On-Line Startup Commisioning<br />
• On-site machine trouble - shooting bearing & vibration<br />
problems.<br />
• Vibration / Balancing / Alignment Training Courses.<br />
• Precision Dynamic Balancing service of rotors up to 3-5Kg.<br />
NVMS Measurement<br />
Systems<br />
info@nvms.com.au<br />
www.nvms.com.au<br />
<br />
CM PRODUCTS<br />
Noise & Vibration Measurement Systems PTY Ltd (NVMS) represents<br />
only the world’s leading manufactures - Brüel & Kjær S&V, Brüel & Kjær<br />
Vibro, Hottinger Baldwin Messtechnik (HBM), Sensear, FLIR Systems<br />
– and our own world-class project engineering.<br />
Compact Vibration Monitor - VIBROCONTROL 1500 (VC-500)<br />
Ideal for monitoring on pumps, fans, motors, blowers,… it fills the gap<br />
between high end vibration monitoring and ordinary vibration switches.<br />
VC 1500 captures also trends casing vibrations, rolling-element bearing<br />
and temperature condition and even provides frequency information in<br />
one device.<br />
Machine protection & CM VIBROCONTROL 6000 (VC-6000);<br />
Offers the highest flexibility for machine protection and online condition<br />
monitoring. The latest hardware platform ensures highest channel<br />
density for hundreds of channels with the world fastest reaction time of<br />
10ms in online machine condition monitoring.<br />
Online Machine CM User interface - COMPASS 6000;<br />
Is a modern windows based user platform for comprehensive conditionbased<br />
machine monitoring and diagnostic on critical machines like<br />
Turbines, Compressors, Generators,…tools like Envelope, FFT, CPB<br />
spectra, Orbit, Waterfall plots … describe only a few of the capabilities<br />
to detect machine failures in a very early stage.<br />
Portable Vibration Analyser - VIBROTEST 60 (VT-60);<br />
Is a combination of vibration Analyser, data collector and balancing<br />
device.<br />
Online CM in harsh environment - VDAU-6000:<br />
This 16 channel powerful system comes in an IP65 enclosure and<br />
provides Zone II ATEX Certification. Fits perfect in hazard areas as<br />
required as on mine sides and offshore platforms. The installation<br />
can be carryout close to the rotating equipment. Machine data can be<br />
transfers wireless / hardwired into a server.Alarming and diagnostic<br />
capabilities helps to plan maintenance ahead.<br />
SENSORS and Accessories: for the various diagnostic & monitoring<br />
tasks we have over 1000 products available including a large range<br />
of transducers, accelerometers, velocity/displacement sensors and<br />
probes.<br />
Equipment for structural durability, stress analysis and testing:<br />
HBM’s product range covers strain gauges, torque, pressure, load cells<br />
Vol 24 No 3
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<strong>AMMJ</strong><br />
27<br />
2011 CM Equipment and Services<br />
noCrops<br />
transducers, amplifiers and rugged data acquisition systems as well as<br />
software for structural durability investigations, tests and analysis.<br />
Thermal imaging cameras – Flir:<br />
Detect problems on bearings, electrical circuits, fuses…with the world<br />
leaders in thermal imaging.<br />
CM Services<br />
NVMS has developed it’s service and project support reputation through<br />
a close partnerships with our valued clients and suppliers.<br />
Each customer has unique requirements, so the “one size fits all”<br />
product/service concept simply doesn’t apply to plant-wide monitoring<br />
applications.<br />
We provide extensive “full circle” service and support packages that<br />
closely match the specific requirements of a wide range of industries<br />
and machines, and these can be easily fine-tuned to the customer’s<br />
specific application.<br />
• Instrumentation for machine protection and condition based<br />
monitoring<br />
• Support and implementation of predictive maintenance<br />
strategies<br />
• Engineering and Design<br />
• Project management<br />
• Performance monitoring<br />
• Installation and commissioning<br />
• Test and Measurements solutions for structure Analysis and<br />
durability<br />
• Service and products in all industries Power/Oil & Gas<br />
/Mining/Wind/Solar power<br />
• Industry recognised training courses tailored to your<br />
requirements in our own training facility in Perth.<br />
• NATA accredited calibration lab<br />
SIRF Roundtables<br />
peter.todd@sirfrt.com.au<br />
Web Page: www.sirfrt.com.au<br />
CM SERVICES<br />
SIRF Roundtables facilitates regional shared learning networks across<br />
Australia and New Zealand for organisations seeking best business<br />
performance.<br />
Membership groups include the Industrial Maintenance Roundtable<br />
(IMRt), Manufacturing Excellence Roundtable (MERt), Knowledge<br />
Management Roundtable (KMRt) and Sustainability Roundtable (SARt).<br />
Services related to condition monitoring include:<br />
· Facilitates the sharing of Condition Monitoring best practice<br />
between IMRt/ MERt members<br />
· Coordinates the annual Condition Monitoring & Lubrication<br />
Forum eg. October 17 & 18 2011 in Sydney<br />
· Training on Management and Operation of CM & Inspection systems<br />
for non-specialists<br />
· Training on Basic Condition Monitoring for non-specialists<br />
· Carrying out Predictive Maintenance Strategy Reviews<br />
SIRF Roundtables annually runs a National Forum on Condition<br />
Monitoring and Lubrication. It is an opportunity to listen to leading<br />
industry practitioners on techniques and proven strategies they use in<br />
their operation.<br />
Attendees learn from the presentations & discussion groups and are<br />
able to take back tips and ideas and adapt into their own environment.<br />
The forum provides not only a learning platform but also many networking<br />
opportunities amongst delegates with similar roles and challenges so<br />
people can learn from one another.<br />
Leadership has a class of its own<br />
FLIR E-Series: Picture Perfect<br />
A new generation of FLIR hand-held ‘point & shoot’<br />
thermal imagers is here. Packed with class leading<br />
features, the E-Series is designed for applications including<br />
electrical, industrial, mechanical, HVAC and building.<br />
Take your pick of three pixel resolutions – all with 60Hz<br />
frame rate and a 3.0 Meg visual camera built in.<br />
The new FLIR E-Series. It’s all class.<br />
Get Connected!<br />
Connect to iPhone or iPad via Wi-Fi<br />
to use the FLIR ViewerApp for<br />
processing and sharing results.<br />
◊ Mobile Device Wi-Fi Connectivity<br />
◊ Built-in Digital Camera & Laser Pointer<br />
◊ Superior Point & Shoot<br />
Thermal Imagery<br />
◊ Large Bright Touchscreen<br />
◊ Groundbreaking Performance<br />
& Affordability<br />
FLIR Systems Pty Ltd.<br />
10 Business Park Drive, Notting Hill, VIC 3168, Australia<br />
VIC: 03 9550 2800 NSW: 02 8853 7870 WA: 08 6263 4438<br />
QLD: 07 3861 4862 SA: 08 8274 3747<br />
Tel AU: 1300 729 987 NZ: 0800 785 492<br />
Email: info@flir.com.au www.flir.com<br />
ISO No. FLIR20837<br />
Vol 24 No 3
Vol 24 No 3<br />
<strong>AMMJ</strong><br />
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2011 CM Equipment and Services<br />
SKF Australia<br />
R.S.Senthil.Vel@SKF.COM<br />
www.skfcm.com/reliability<br />
CM PRODUCTS<br />
SKF is the leading supplier of condition monitoring and maintenance<br />
diagnostic systems, hardware and software that enables us to monitor<br />
operations and identify problems both mechanical and electrical faults.<br />
1. Basic Condition Monitoring<br />
SKF Basic condition monitoring kits combine instruments to enable a<br />
“multi-parameter” approach to monitoring that includes vibration, oil<br />
condition, temperature, speed, and more to help ensure the accurate<br />
and reliable assessment of machine condition.<br />
2. Portable data-collectors/Analyzers for Condition Monitoring<br />
SKF offers a wide variety of portable data collectors/analyzers including<br />
data collection, machinery vibration analysis and monitoring, early<br />
detection of bearing defects or gear tooth wear, electric motor monitoring<br />
and field machinery balancing. Easy menu selection and control enable<br />
the user to quickly and efficiently perform a wide variety of operations.<br />
3. Online Surveillance condition monitoring systems<br />
SKF’s On-line surveillance systems complement the use of periodic<br />
data collection instruments, facilitating a round-the-clock monitoring of<br />
machinery that collects data 24 hours per day, 7 days per week from<br />
permanently installed sensors.<br />
4. On-Line Machinery Protection Systems<br />
SKF Condition Monitoring offers a spectrum of machinery protection<br />
and monitoring solutions backed by decades of experience and global<br />
support that includes monitoring, protection, analysis and diagnosis of<br />
critical machinery.<br />
5. Baker Motor Testing and Diagnostic Systems:<br />
SKF acquired Baker Instruments in June 2007. Baker Instruments<br />
Company is dedicated in developing and manufacturing motor<br />
reliability tools that offer a broad spectrum of capabilities. Dynamic<br />
(on-line) monitoring combined with comprehensive static testing (offline),<br />
enhances motor condition awareness including efficiency and<br />
performance information<br />
6. Measurement and Laser alignment Systems:<br />
SKF is an exclusive distributor for Easy-Laser, precision laser alignment<br />
system for industrial applications. SKF also offers a suite of other<br />
complimentary products such as Online and Offline Thermography<br />
systems, Ultrasonic Inspection kits, low cost vibration sensors etc.,<br />
CM SERVICES<br />
SKF RELIABILITY SYSTEMS<br />
SKF offers Asset Efficiency optimization (AEO), a management process<br />
designed to achieve maximum efficiency and effectiveness from<br />
work management activities focused on business goals, increasing<br />
profitability<br />
1. SKF Energy and Sustainability Management (ESM)<br />
This program provides benefits to a customer by establishing an<br />
“opportunity map” of potential savings and improved practices, including<br />
potential areas for:<br />
1. Reducing energy consumption<br />
2. Improving poorly operating energy-intensive systems<br />
3. Improving facility economic performance<br />
4. Improving facility environmental performance<br />
2. Maintenance Strategy.<br />
SKF can assist in developing and implementing maintenance strategies<br />
using the following commonly applied techniques:<br />
1. RCM: Reliability Centered Maintenance:<br />
2. SRCM®: Streamlined Reliability Centered Maintenance:<br />
3. RBM: Risk Based Maintenance<br />
3. Work identification.<br />
For increasing plant reliability SKF recommends following processes/<br />
programs to identify appropriate maintenance tasks:<br />
1. Operator Driven Reliability (ODR):<br />
2. SKF Predictive maintenance (PdM)<br />
3. SKF Proactive Reliability Maintenance (PRM)<br />
4. Motor testing and diagnostics service<br />
4. Work Execution.<br />
SKF can assist by providing project management, supervision, and<br />
inspection, mechanical installation skills where customers do not have<br />
either the tools or specialized knowledge in these tasks.<br />
1. Application knowledge: SKF has extensive application knowledge<br />
through branch offices around Australia, as well as the industrial<br />
specialists to draw on to solve customer problems with regards to<br />
rotating equipments.<br />
2. Reliability Training: SKF engineers are on hand to provide specialist<br />
knowledge and training for our customers. We have offices both globally<br />
and locally, as one of largest global suppliers of condition monitoring/<br />
reliability services.<br />
Vitech Reliability<br />
info@vitechreliability.com<br />
www.vitechreliability.com<br />
Vitech Reliability has been providing a specialist approach to condition<br />
monitoring and reliability based technologies in Australia since 1994.<br />
We service Australia, New Zealand and South East Asia with offices in<br />
Perth, Melbourne and Brisbane.<br />
Vitech Reliability provides accurate, durable and cost effective<br />
solutions designed to ensure customers improve overall reliability and<br />
productivity.<br />
CM PRODUCTS<br />
Commtest<br />
Developers of the revolutionary:<br />
• Vb Series portable data collectors, analysers and balancing<br />
systems.<br />
• Vb Online multi-channel plant surveillance systems.<br />
• Ascent analysis / data management software.<br />
Fixturlaser<br />
Leaders in laser shaft alignment and specialist measurement<br />
solutions.<br />
• XA - Shaft alignment system<br />
• PAT - pulley alignment tool<br />
• Dirigo - entry level alignment systems<br />
• OL2R - dynamic movement measurement system<br />
• Roll and Geometric alignment systems<br />
Vibro-Meter CM Systems<br />
Vibro-Meter provides advanced and highly reliable sensing, protection<br />
and condition monitoring systems for thousands of high capital rotating<br />
machines worldwide. Superior quality sensors for harsh environments<br />
as well as high performance condition monitoring systems and software.<br />
Vibro-Meter’s VM600 platform integrates all protection, condition and<br />
performance monitoring functions in a single system.<br />
Wilcoxon Research<br />
For over 40-years manufacturers of accelerometers, vibration sensors,<br />
and accessories for industrial condition<br />
based monitoring (CBM) applications.<br />
• Industrial accelerometers, cables and terminations solutions<br />
• 4-20mA loop powered Transducers<br />
• Signal Conditioners<br />
Vol 24 No 3
Vol 24 No 3<br />
<strong>AMMJ</strong><br />
29<br />
2011 CM Equipment and Services<br />
SDT Ultrasound Systems<br />
Portable ultrasound instruments designed for predictive maintenance.<br />
Mobius - iLearn Interactive<br />
Innovative and interactive computer-based vibration and shaft alignment<br />
training products, vibration analysis tools and vibration certification<br />
courses.<br />
• iLearn Vibration<br />
• iLearn Alignment<br />
• Distance Learning<br />
FLIR Systems<br />
The global leader in Infrared Cameras, offer a wide range of low<br />
cost, innovative and high end Infrared Cameras for Predictive and<br />
Preventative Maintenance. These include:<br />
• InfraCam and InfraCam SD – Low cost portable infrared cameras<br />
Beran Instruments<br />
Manufacturers of online and portable turbine diagnostic and monitoring<br />
solutions.<br />
• 767 - 32-ch portable multi-channel diagnostic and motoring system<br />
• 766 - 32-ch on-line multi-channel diagnostic and motoring system<br />
Endevco<br />
World leaders in extreme vibration and pressure sensing technologies.<br />
• Extreme temperature industrial accelerometers<br />
• Precision pressure transducers<br />
• Test & measurement accelerometers<br />
DMSI - Condition Based Maintenance Systems<br />
Providers of integrated maintenance software solutions.<br />
• Maintelligence Asset Management<br />
• MAINTelligence Condition Monitoring<br />
• Maintelligence / Inspect CE PDA portable inspection devices<br />
PDMA<br />
Electric motor and generator testing systems / asset management.<br />
• MCE – Offline motor testing<br />
• Emax – Online motor testing<br />
• MCEmax – Combined tester<br />
Artesis<br />
Online motor condition monitoring systems<br />
• MCM Online motor monitors<br />
• MCM Scada motor management software<br />
Baseline Series<br />
Vibration tools and termination products.<br />
• BLS-UVLA vibration listening amplifier for data collectors or<br />
stand alone stethoscope use.<br />
• BLS-TB series accelerometer termination boxes<br />
• Assorted accelerometer mounting hardware.<br />
CM SERVICES<br />
Vitech Asia Pacific provides the following service:<br />
• Product, VA and Alignment Training (class room & customised<br />
on site)<br />
• Installation & Commissioning of systems<br />
Condition Monitoring and Lubrication National Forum<br />
Turbo Charge your CM with Defect Elimination<br />
This annual event is widely recognised for its role in best practice sharing<br />
in the Australasian Reliability, CM & Lube community<br />
Event Overview:<br />
3 streams (Reliability, Lube, CM Case Studies) with 26 separate presentations<br />
Networking activities including breakout discussions<br />
3 day Post Forum Workshops on Lube Management & Vibration Analysis<br />
(ISO VA Cat II Refresher & CMSkills Exams)<br />
Over 20 exhibitors from the reliability and CM industry<br />
Keynote Speakers:<br />
Global Director, Hatch’s Operational Services group.<br />
presents: Eliminate Future Failures through Defect Elimination<br />
Founder of Mobius Institute and supports vibration analysis<br />
training programs in 33 countries. Presents ‘Bringing Reliability into the Predictive<br />
Maintenance Program’<br />
17th and 18th October<br />
Bankstown Sports<br />
Conference Centre Sydney<br />
Topics Presented by industry leaders<br />
Vibration Analysis Case Studies<br />
Reliability Improvement Techniques<br />
Lube Contamination and Testing<br />
Proven Defect Elimination Approaches<br />
Lubrication Management<br />
Program Management and KPI’s<br />
Mechanical & Electrical Thermal Imaging<br />
Integration of different CM techniques<br />
<br />
Contact us:<br />
Michelle Todd<br />
Tel: + 61 (0) 0407 723 133<br />
michelle.todd@sirfrt.com.au<br />
www.sirfrt.com.au & select National Forums<br />
Vol 24 No 3<br />
Adver.indd 3<br />
6/10/2011 4:57:13 PM
Maintenance Decision Support Project<br />
At A Chemical Plant<br />
Ron Jenkins of Orica Australia,<br />
Murray Wiseman and Daming Lin of OMDEC Inc Canada<br />
Abstract - Does condition monitoring deliver the results you expect. Can we sharpen the saw and make a more<br />
informed reliability decision? This project investigated the use of a Maintenance Decision Support tool and how it<br />
may be used to improve reliability decisions based upon failure prediction. Data collection and manipulation proved<br />
to be the single most challenging issue. The accuracy with which failures are reported in the CMMS and the need to<br />
understand which failure modes actually occurred and whether they really failed or were suspended was shown to be<br />
of prime importance if reliability analysis was to succeed. The effort needed by the Reliability Engineer in performing<br />
reliability analysis pales in comparison to that required for the cleansing of the data and for its transformation into<br />
analyzable form. Once good data emerges from the anarchy of styles used within the CMMS, software makes light<br />
of the task of detailed reliability analysis that will enable good maintenance decisions.<br />
INTRODUCTION<br />
This paper provides an insight into the challenges faced by the Reliability Engineer before he can exploit Maintenance<br />
Decision Support software. The intent of this study is to apply such a tool (EXAKT© CBM Decision Optimization www.<br />
omdec.com/wiki) to critical magnetic pumps at the Orica Laverton North Chloralkali Plant in Australia. Conditioning<br />
Monitoring (CM) already existed. Nevertheless unexpected failures have occurred and the need to validate and<br />
improve on the CM process was paramount. Reliability based decisions may be assisted with specific types of data<br />
relating to equipment operation and maintenance. However, it is important to recognize that large volumes of CM data<br />
are no guarantee of good condition based maintenance decision models unless that data reflects the deterioration of<br />
failure modes that actually occur. How do we know what condition monitoring variables are significant? This project<br />
will attempt to use a software tool that analyses CMMS failure data in conjunction with condition monitoring data in<br />
order to identify those monitored variables that influence the probability of occurrence of the targeted failure modes.<br />
The methodology applies a Proportional Hazard Model (PHM)(see Ref 8) to determine not only which monitored<br />
variables are significant but also the precise probabilistic relationship between those variables and equipment failure.<br />
The main objective of this study is to understand the nature<br />
of the data required for this. The paper will discuss a data Tag<br />
Pump Description<br />
acquisition, cleansing and transformation philosophy for P12111A Catholyte Pump A<br />
condition monitoring programs that supports practical<br />
P12111B Catholyte Pump A<br />
decision making in maintenance.<br />
P13005 Caustic Evaporator Feed Pump<br />
SCOPE<br />
The study was limited to four pump sets over two years,<br />
an admittedly small sample. These pumps are all Iwaki<br />
magnetic pumps with Toshiba induction motors on caustic<br />
service as detailed in Table 1 opposite.<br />
RELIABILITY PREDICTION MODELS<br />
There are many reliability prediction software tools on the<br />
market. A basic search on the web reveals a number of<br />
vendors [1], [2], [3] for example. This project aims to trial<br />
one such program, EXAKT© because it is one of the few<br />
that confronts the challenge of achieving verifiable dayto-day<br />
decisions based upon the two principal available<br />
maintenance data sources: the CBM database(s) and the<br />
CMMS database.<br />
Reliability prediction is not new. One of the most widely<br />
recognised models was developed by Weibull in 1951<br />
[4]. He developed a failure analysis method that provided<br />
reliability predictions as well as the level of confidence with<br />
which those predictions may be applied.<br />
P13006 Intermediate Caustic Pump<br />
P12111AM Catholyte Pump A Motor<br />
P12111BM Catholyte Pump B Motor<br />
P13005M Caustic Evaporator Feed Pump Motor<br />
P13006M Intermediate Caustic Pump Motor<br />
Table 1<br />
EXAKT trial sample set<br />
Weibull Distribution - Three of its forms<br />
Weibull also showed that the shape parameter in his equation (above) relating reliability to age provides an indication<br />
of likely failure behavior. For a shape parameter of
<strong>AMMJ</strong><br />
Maintenance Decision Support Project 31<br />
material quality, incorrect installation, or faulty start up procedures. If =1 the failure behavior is random, meaning<br />
that the failure rate (or conditional probability of failure) is constant and does not change with age or usage. Finally,<br />
for >1, the Weibull model predicts that the failure rate will increase with age due to wear out. Based on the<br />
Weibull model having determined that =< 1 it may be concluded that age based replacement programs, rather<br />
than improve performance, could, on the contrary, lead to unnecessary costs, downtime, and poor reliability. If a<br />
maintenance strategy called for a randomly failing component (with = 1) to be replaced preventively at an interval<br />
equal to its MTBF = , then 63% of the time that component would fail prior to PM.<br />
To develop a Weibull model we need only determine (estimate from historical data) values for the parameters <br />
and . The model will yield a variety of data points revealing of the relationship between age and reliability. These<br />
relationships when represented graphically help us understand the age based failure behaviour of items and, more<br />
usefully, their failure modes.<br />
The problem with age<br />
based analysis<br />
With basic Weibull (age<br />
based) analysis practical<br />
decision making will<br />
often be problematic if<br />
populations are mixed<br />
or varying conditions<br />
influence individual units<br />
in the sample. In those<br />
cases basic Weibull<br />
analysis will tend to<br />
underestimate the shape<br />
parameter leading to<br />
underestimation of the<br />
equipment life. Figure 1<br />
and Figure 2 illustrate a<br />
general problem when<br />
maintenance engineers<br />
use an age-based<br />
analysis for proactive<br />
decision making.<br />
The analysis can often<br />
lead to higher than<br />
necessary preventive<br />
replacement frequencies<br />
and costs. Apart from<br />
the problem of mixed<br />
populations, making<br />
individual unit repair-now<br />
or continue-to-operate<br />
decisions armed only<br />
with an item’s age is of<br />
little value in day-to-day<br />
operations. Age in the<br />
age-reliability plot is, in<br />
essence, a mixture that<br />
averages out the effects<br />
of other influential yet<br />
unspecified variables.<br />
Age alone, therefore,<br />
obscures the influence<br />
of a unit’s individual<br />
operating conditions<br />
and its current state as<br />
reflected by its condition<br />
monitored data. This<br />
reality has lead to a<br />
maintenance strategic<br />
approach known as<br />
Condition Based<br />
Maintenance (CBM).<br />
<br />
Figure 1<br />
Weibull analysis of individual and combined data sets.<br />
Figure 2 Early life probability graphs of individual and mixed populations – 3 sets of data<br />
each yielding a Weibull shape factor of 4.51. The Weibull analysis of the mixed population,<br />
however, yields a lower shape factor of 2.46, with significant impact on predicted life. (Ref 7).<br />
Vol 24 No 3
<strong>AMMJ</strong><br />
Maintenance Decision Support Project 32<br />
How can Weibull analysis be extended to cover CBM?<br />
Proportional Hazard Modelling (PHM) extends the Weibull method to cover today’s CBM reality. It resolves the<br />
problem of mixed populations by including, not only age, but also other significant differentiating factors (operational<br />
and monitored) in the analysis. The procedure makes use of today’s inexpensive personal computers to handle the<br />
intensive computational requirements<br />
PHM attempts to “sharpen the saw” by using all available significant prediction factors. These include other plant data<br />
obtained from condition monitoring and operational records. The modelling process tests for failure predictability from<br />
each available data source. It attempts to identify the significant variables that influence the probability of occurrence<br />
of the failure modes of interest.<br />
The outcomes from this approach would typically reduce the Weibull shape parameter such that age based<br />
decisions will be superseded gradually (as information management procedures improve) by condition based<br />
decisions. Such an evolution in maintenance practice is desirable because condition based decisions tend to be<br />
more N1 conservative and less costly in the long run than age based decisions. This is due primarily to the fact<br />
that CBM tasks (when executed using a decision model based on significant variables) detect potential failures<br />
whereas age based preventive maintenance tasks, even if performed excessively frequently, do not totally exclude<br />
the possibility that some items will fail functionally. The consequences are higher costs.<br />
Confidence in CBM prediction is a function of how correlated the condition monitoring variables are to the failure<br />
modes’ deteriorations. The existence of such correlations can be determined when failures and suspensions N2 are<br />
accurately distinguished from one another in the CMMS.<br />
Figure 3A<br />
Business factors when combined with the proportional hazard model yield an optimal<br />
decision chart (Figure 3A). The chart plots the progressive likelihood of failure and<br />
of risk. “Risk” combines both probability and cost. A “crossover” point suggests the<br />
optimal moment for repair. The user may set his optimizing objectives in the model.<br />
For example, the objective (of a given CBM task relevant to a given failure mode)<br />
may be set for maximum cost, availability, profitability or a desired mix of all three.<br />
The method also provides a remaining useful life (RUL) estimate and confidence<br />
interval (Figure 3B) independently of economic factors.<br />
Figure 3A Optimal decision chart: Vertical axis: the weighted<br />
sum of the values of each CBM variable determined to be significant<br />
in the model. Horizontal axis: the current age of the item. Green<br />
area: No action. Yellow area (small area between the green and red<br />
boundaries): Action required in a specified time. Red area: Action<br />
recommended as soon as possible (Item is in a “Potential Failure”<br />
state).<br />
Figure 3B Conditional Probability Density: Provides estimation<br />
of Remaining Useful Life (RUL) and confidence (standard deviation)<br />
based solely on probability.<br />
A decision model, such as that illustrated in Figure 3, which is based<br />
both on cost and probability will identify the most cost effective<br />
moment of intervention (given the current working age and the most<br />
recent levels of the significant monitored variables).<br />
The two most important organizational requirements for CBM modelling (or for any form of data based reliability<br />
analysis for that matter) are that:<br />
1. The failure modes be well identified on the completed work orders, and that<br />
2. The distinction be made between failure (or impending failure) and preventive replacement (suspension of a<br />
component’s life cycle).<br />
Figure 4<br />
In a “proportional hazard model (PHM) analysis, the<br />
equation of Figure 4 is numerically solved.<br />
The Weibull model containing the shape and scale <br />
parameters is extended by an exponential factor that<br />
contains the parameters associated with each<br />
significant CBM monitored variable in the vector<br />
Z i (t).<br />
Figure 3 B<br />
The software applies statistical tests for the model fit and for the significance of variables associated with the failure<br />
modes and for the overall model’s goodness of fit.<br />
Vol 24 No 3
<strong>AMMJ</strong><br />
Maintenance Decision Support Project 33<br />
DATA COLLECTION & SCREENING<br />
The phrase “rubbish in equals rubbish out” could not be more applicable when attempting to analyse data using a<br />
software reliability analysis tool. With PHM based analysis data quality is of great concern for the reason that the<br />
results of the analysis are intended to be used day-to-day for practical decision making.<br />
The user of the software must have a good understanding of the equipment under analysis, its failure modes, and<br />
the monitored variables likely to be influential factors that reflect failure mode deterioration. The software confirms or<br />
refutes such assumptions using intensive computations based on statistical techniques. If the hypothesis that a CM<br />
variable is significant is confirmed (not rejected at the 5% significance level) by the software, the reliability engineer<br />
will obtain a probabilistic relation among:<br />
1. significant variables, 2. working age, and 3. component failure probability.<br />
Subsequently, the method applies a “predictive” algorithm N3 in combination with the PHM to generate a Remaining<br />
Useful Life Estimation (RULE) model. Once developed and accepted the model will be deployed as an agent<br />
“watchdog” silently scanning condition monitoring data as it appears in designated database locations. The agent<br />
writes the results into a database table accessible to the Reliability Engineer and the Maintenance Manager via the<br />
normal CMMS reporting system.<br />
Failure data<br />
At the Laverton site a computerised maintenance management system (CMMS) is used to raise work orders, issue<br />
permit to work forms and report equipment failure history. Fields available to be completed on work order closeout<br />
include “observations, cause, components and comments”.<br />
The data extraction process for the pumps found comments ranging from general statements such as “removeddamaged”<br />
to observations like “OK”. In many cases there was no attempt to identify failure modes or causes (e.g.<br />
dry running or cavitation) or to distinguish between a potential failure and a suspension. We at Orica hasten to<br />
point out that the technicians themselves are not to “blame” for such communication gaps. CMMS trainers focus on<br />
the mechanics of manipulating the software rather than on encouraging precise RCM styles of expression of field<br />
observations into readable descriptions of as-found equipment state. As a result, given the pride in their work held<br />
by technicians, their commentary text includes largely descriptions of “what I did” and fewer descriptions of “what I<br />
found”. Both, of course, are required for Reliability Analysis.<br />
The data available from the CMMS was, therefore, unsuitable for loading directly into the reliability analysis software.<br />
Two obstacles were encountered. Firstly, the structure of the CMMS data is not that which is needed for generating<br />
a sample. A sample of life cycles (discriminating between ending-by-failure and ending-by-suspension) is necessary<br />
before reliability analysis can be performed. The issue was resolved relatively easily using data mapping and<br />
transformation algorithms (illustrated in Figure 5).<br />
Figure 5 Transformation of CMMS data to a<br />
Because a sample is a collection of life cycles it is<br />
Sample for Reliability Analysis<br />
impossible to develop a sample directly from the<br />
CMMS’s structural representation of work order<br />
history. Figure 5 indicates that the data in the<br />
CMMS must be transformed to a structure wherein<br />
life cycles are identifiable and countable.<br />
Both complete and partial (suspended) life<br />
cycles in the sample must be accounted for by<br />
the reliability analysis procedure or software.<br />
Furthermore the best way to ensure an unbiased<br />
sample is to select two points in calendar time that<br />
define the sample window. One selects the window<br />
width such that there are a sufficient number of life<br />
cycles for analysis.<br />
Sufficiency depends on several factors one of<br />
which is how closely the condition monitoring data<br />
reflects the true health state of a given failure mode.<br />
External variables reflecting operating context<br />
within mixed populations should be identified and<br />
accounted for in the model.<br />
The second obstacle, on the other hand, is far more daunting. In some cases it was difficult to determine if the pump<br />
had failed or if the work order represented a suspension. Mistaking a suspension for a failure will mislead the analysis<br />
and modelling into mistakenly associating preventive repair with failure. That is, the model will “try” to correlate values<br />
of condition monitoring variables occurring at a time when the component is actually in good condition, with, a failure<br />
event. This will have the effect of introducing scatter (i.e. lowering confidence) in the model’s predictive capability.<br />
Vol 24 No 3
<strong>AMMJ</strong><br />
Maintenance Decision Support Project 34<br />
The most basic data requirement, therefore, of reliability analysis (Weibull, PHM, and most others) is to distinguish<br />
between failure and suspension when reporting the as-found condition of each significant failure mode encountered<br />
during the execution of a work order.<br />
In any reliability study the working age of the equipment is important. Working age is a reference line measuring the<br />
accumulated usage of, or stress on, a component. The engineering units selected for working age should reflect the<br />
accumulated normal wear and tear on the component. Calendar age is appropriate when the equipment operates<br />
more or less uniformly. Energy consumed or production units delivered often provide a better indication of true<br />
working age. Pump operating hours were not easily available and had to be estimated based on the date of the work<br />
order and known operating practices for the pumps. For example, the two catholyte pumps shared the same duty<br />
and swapped from online to standby every two weeks. Knowing this, the working age could be estimated based on<br />
calendar dates, average plant uptime, and 50% run time. The other two pumps ran continuously and the working life<br />
was based directly on the work order’s date.<br />
Vibration data<br />
Condition monitoring (CM) on site has been used for over 9 years. This includes vibration analysis (VA) of all pump<br />
sets, fans and compressors. The CM is conducted by a specialist external contractor. Critical drives that have standby<br />
redundancy are changed over regularly to ensure that they still run. Standby units are started up to perform VA. The<br />
VA data is compiled by the Contractor and an executive summary forwarded to Laverton each fortnight.<br />
The VA report attributes to each of the rotating machines a performance rating of “1” to “5”. When machines reach<br />
level 3 we begin to monitor closely, at level 4 we plan to replace at next opportunity and if level 5 we would replace<br />
immediately. No “scoreboard” is kept to tally hits, misses, and false alarms by this condition monitoring program.<br />
(Doing so, in a “Living RCM” N4<br />
project, is an important conclusion of this study.)<br />
If the VA reported equipment condition is so severe and a decision to replace is made, it will have significant production<br />
impact. An example is a magnetic drive pump motor on the Catholyte system that was exhibiting excessive noise. A<br />
decision was made to replace the motor rather than risk an unplanned trip (potentially occurring only hours later).<br />
When faced with a decision to shutdown and replace an item the level of confidence in making that decision is, for the<br />
aforementioned reasons, not known. Some pumps have been known to run for extended periods at high vibration<br />
levels without the need for replacement. This implies that factors, others than those reported by VA, influence failure<br />
probability. It is incumbent then, upon the organization and its reliability engineers, to identify, through observation<br />
and analysis, those internal and external factors likely to influence production and profitability.<br />
Operational History<br />
Another source of information was obtained from the plant Distributed Control System (DCS) alarm history logs. This<br />
source of data assisted with confirming pump working ages by flagging stop and start events.<br />
DATA CLEANSING & TRANSFORMATION<br />
Data Cleansing<br />
Before using reliability analysis software a number of steps are required to cleanse and transform the data.<br />
1) Prepare or update the FMEA for pump and motor. The FMEA constitutes a “knowledge base” each record<br />
of which describes a failure mode whose behavior is to be determined by the “counting up” (i.e. basic reliability<br />
analysis) of the work order instances of that failure mode.<br />
2) Identify the failure modes from the work orders and link them to the FMEA. Each link represents an ending<br />
and beginning event in the sample.<br />
3) Correlate VA data to the pump failure and suspension events using a technique such as PHM.<br />
4) Ensure that any PM activities are properly allocated to either suspension or failure events of the pumps.<br />
5) Use the DCS recorded stop/start events, if necessary, to determine pump working age at each life event (i.e.<br />
work order).<br />
6) Before modelling use the data validation function in the software to locate, repair or eliminate erroneous and<br />
illogical data. A common example of the latter would be an Event or Inspection record containing a working<br />
age at a later date that is lower than a working age at an earlier date.<br />
7) Create beginning events where life cycles began prior to start date of the sample window.<br />
8) Ensure that failures and suspensions are accurately identified and distinguished. Confirmed “potential”<br />
failures should be counted as failures. Well discussed maintenance department standards should distinguish<br />
failures from suspensions.<br />
Surprisingly, Failure Mode Effects Analysis (FMEA) for the basic magnetic pump and even the standard induction<br />
motor were difficult to find in public sources. Many references to the method are available however no specific<br />
analysis could be found. The study developed a FMEA model (by mining the work order history) for the pumps and<br />
Vol 24 No 3
<strong>AMMJ</strong><br />
Maintenance Decision Support Project 35<br />
motors and this was used to identify the significant failure modes of interest. One of the surprising outcomes from the<br />
pump analysis was that pump failures were largely related to operational factors rather than to intrinsic mechanical<br />
defects.<br />
The next step was to link the CMMS data associated with failures with the different failure modes from the FMEA.<br />
Refer Table 2. One important step is to assign the work order history with beginning and end dates for pump or motor<br />
events, paying particular attention to failures or suspensions. Refer Table 4. This step including preparation of the<br />
Events table should be automated through a “living” RCM process and supporting software. Ref. 6<br />
Table 2<br />
Some failure mode data from the work orders<br />
RCM REF ITEM EFFECTS CONSEQ W.ORDER<br />
LRR Pump A See service report filed in planning office<br />
Pump PM<br />
O 28618<br />
FMM1 Motor A Ageing wear Replaced motor. Tested ok. O 24115<br />
FMM1 Motor A Possible problem was found with the magnetic coupling lose on the<br />
motor shaft. The coupling and pump case was found with scuff marks<br />
showing that the coupling was or had been touching the casing.12/3<br />
Isolated and disconnected motor. Bolted and bagged tails. Motor sent<br />
to Bob White Electrics for bearing change ane inspection. 13/3<br />
Reconnected motor and Meggered motor, cable and checked earth<br />
return ..all ok ...R Bennett<br />
O 12772<br />
NRRM Motor A Motor noisy Greased & monitored - OK O 35076<br />
FMP1 Pump B Removed pump & found that the PTFE had worn off behind the<br />
impellor & coursed a leak path past the split plate, Replace split plate,<br />
impellor & bearings, Reassemble & reinstalled back to service.<br />
FMP6 or S Pump B Pump body gasket leaking Gasket looked to be OK with no obvious<br />
leak path<br />
O 17885<br />
O 23271<br />
FMP2 Pump B Leak Caustic was leaking out of the drain hole in the pump housing.<br />
repaired Including electrical disconnection of pump motor. - pumps<br />
impellors front face had sheared off completely and the PTFE had got<br />
into the mag drive and seized the pump up causing a h<br />
O 31096<br />
Table 3<br />
Vibration data<br />
Table 4<br />
Some work order records with RCM reference and Event type indicated<br />
Vol 24 No 3
<strong>AMMJ</strong><br />
Maintenance Decision Support Project 36<br />
RESULTS<br />
The study did not identify any vibration variables that had strong association with the failures reported. In fact the<br />
results indicate that most failures were due to operational techniques, rather than to mechanical deterioration. This is<br />
considered a valuable finding of the study as it does indicate the area on which to focus asset management training<br />
as well as the CBM program itself. For the former, a lesson is to spend more time in training operators on correct<br />
pump operation. For the latter, we may examine the returned value of the VA program. It is recommended to track<br />
(through a living RCM process) VA’s good and bad calls in order to have an evaluation of the program’s predictive<br />
performance. Such an evaluation, consistent with continuous improvement, will result in more a more effective CBM<br />
program. The objectives of improvement are<br />
1) Discrimination of failure and suspension leading to more dependable decision models, and<br />
2) determination of vibration or other condition monitoring extracted features that reflect actually occurring<br />
failure modes.<br />
CONCLUSIONS<br />
This was a preliminary study based on a small sample of pumps operating over only a two year period. The authors<br />
intend to expand the sample and to apply the lessons learned relative to the management of failure and suspension<br />
data, particularly the following:<br />
1. Improve the management of the work order to RCM relationship by identifying both the failure mode and<br />
the Event type (either PF, FF, or S) on the work order.<br />
2. Report the failure mode as a reference to a FMEA record where it is defined in the context of the<br />
Function, Functional failure, and Effects.<br />
3. Include in the free text field of the work order both “what was found” as well as “what was done”.<br />
4. Update the FMEA dynamically, based on day-to-day observations surrounding the execution of a work<br />
order. The work order free text should, to the extent justified, support updates to the Effects text field of<br />
a FMEA/RCM record in a continuous process of knowledge refinement. The work order free text should<br />
be examined by the reliability engineer in order to expand the Effects text of the RCM knowledge base<br />
to cover all reasonably likely situations that may arise in the course of the enterprise’s operations.<br />
Feedback and exchange of these concepts with the technicians should occur regularly.<br />
5. Understand the requirements for an unbiased sample before attempting Reliability Analysis. The<br />
characteristics of a sample for reliability analysis are illustrated in Figure 5.<br />
6. Perform Reliability Analysis. This is, relatively speaking, the easiest part of the entire process as long as<br />
the considerations discussed thus far have been understood and respected by the reliability engineer<br />
and maintenance personnel involved in the work order process.<br />
ACKNOWLEDGEMENT<br />
This paper acknowledges the following people:<br />
For support and encouragement provided by co-authors M Wiseman and Dr D Lin (OMDEC),<br />
For assistance from C Hill (CMA) and S Mustadanagic (Iwaki)<br />
For suggestions from Dr. Naaman Gurvitz (Clockwork Solutions)<br />
REFERENCES<br />
[1] http://www.reliasoft.com/products.htm<br />
[2] http://www.plant-maintenance.com/<br />
[3] http://www.isograph-software.com/<br />
[4] Weibull, W. (1951), “A statistical distribution function of wide applicability”,<br />
J. Appl. Mech.-Trans.ASME 18 (3): 293–297 .<br />
[5] Jardine A.K.S., Banjevic D., Wiseman M.., Buck S. and Joseph T. “Optimising a Mine Haul Truck Wheel<br />
Motors’ Condition Monitoring Program: Use of Proportional Hazards Modelling”,<br />
http://www.omdec.com/moxie/About/cases/<br />
[6] Living RCM and EXAKT forums, http://www.omdec.com/wiki/tiki-forums.php<br />
[7] Mixed Populations Mathematical Basis, Naaman Gurvitz, Clockwork Solutions Inc.<br />
http://www.clockwork-solutions.com<br />
[8] http://www.omdec.com/wiki/tiki-index.php?page=The+elusive+PF+interval<br />
NOTES<br />
N1. “More conservative” in the sense that because CBM (assuming that the CBM detection confidence is high enough) detects “potential”<br />
failures, which, by definition, have few or minor consequences. Hence fewer functional failures, having severe consequences, will slip through.<br />
N2. A suspension is a renewal of a part or component (failure mode) for any reason other than failure. Without making the distinction between<br />
failure and suspension on the completed work order, no data based reliability analysis will be possible.<br />
N3 From the historical records of condition monitoring data, the past transitions from each state to all other states can be compiled in a matrix<br />
and the probabilities of each transition can be thus determined. These probabilities when combined with the Proportional Hazard Model will yield<br />
a failure prediction. For a detailed explanation and more information see Ref 8.<br />
N4 “Living” RCM (LRCM) is a dynamic process whereby work orders are linked to RCM/FMEA knowledge records, each link constituting a data<br />
point in a sample for reliability analysis. Secondly, the RCM/FMEA records should be updated as each work order reveals new knowledge about<br />
a failure and its effects. Ref 6.<br />
Vol 24 No 3
Simple Solutions to Big Problems<br />
Stop The Insanity “TOOL BOX TALK” Courtesy of Ricky Smith<br />
Impact Reliability of your Assets NOW:<br />
Most organizations are looking for the “Silver Bullet”, or a Simple Solution to increase reliability but there is<br />
none. Let’s get back to the basics which will make a large impact on Reliability. Here are some ideas I hope<br />
helps your company increase reliability, lower cost, and save jobs.<br />
Optimizing a company’s lubrication program should be the highest priority.<br />
1. Hire a Professional to come in and conduct a lubrication assessment. Once completed, develop a plan to<br />
implement a world class lubrication program. Ask the lubrication expert to provide training to your people.<br />
2. Ask the expert to come back often until your<br />
lubrication program is in place and effective.<br />
3. Ensure repeatable lubrication procedures<br />
have been written & are being followed by all.<br />
4. Develop a RACI Model for roles and<br />
responsibilities for Lubrication Best Practices.<br />
5. Measure Mean Time Between Failure of your<br />
rotating equipment and watch as reliability<br />
begins to increase quickly. Go to MTBF Users<br />
Guide: www.box.net/shared/1i9v16aq8z<br />
6. Periodically inspect the lubrication program<br />
to ensure the work is performed correctly.<br />
Ensure all maintenance work is performed to a standard.<br />
1. Have repeatable procedures in place for most maintenance work.<br />
Read “Procedure Based Maintenance”at: www.box.net/shared/ke70hvu06f<br />
2. Insure mechanical and electrical technicians use a torque wrench when tightening fasteners and ensure<br />
the correct fastener is used. Use this as a training aid: www.box.net/shared/jrn4tzriyl<br />
3. Every piece of equipment should have work performed to manufacture’s specifications. If not known then<br />
a Reliability Engineer or outside engineer should assist with these specifications.<br />
4. Maintenance supervisors should perform checks on all critical work and at least 10% of non-critical work<br />
each day.<br />
Additional Duty Assignments<br />
1. All maintenance technicians will be given an extra duty every week that enhances the capability of the<br />
crew and should be rotated weekly. (30 minutes at the end of a shift)<br />
2. These duties include:<br />
a. Ensure shop is cleaned at the end of shift.<br />
b. Ensure all special tools are returned to the appropriate place at the end<br />
of the shift and in good working condition<br />
c. Writing Repeatable Procedures will be assigned as an extra duty to a maintenance technician and<br />
will work with the planner to conduct this task. The Reliability Engineer and maintenance supervisor<br />
will approve all procedures before they are to be executed. For help review:<br />
www.alliedreliability.com/gpalliedtraining/details.asp?eventid=46<br />
“TOOL BOX TRAINING” rsmith@gpallied.com Copyright GPAllied www.gpallied.com<br />
Ricky Smith will be joining Len Bradshaw in Australia for the 2011 Maintenance Seminars:<br />
Brisbane 14 – 16 September 2011, Melbourne 19 – 21 September 2011<br />
Go to the following URL for more information: www.maintenancejournal.com/MaintenanceBrochure2011.pdf<br />
Vol 24 No 3
Estimation of Effective Thickness of Corroded<br />
Steel Plates for Remaining Strength Prediction<br />
T. Kaita 1 , J.M.R.S. Appuhamy 2 , M. Ohga 2 and K. Fujii 3<br />
1 Department of Civil Engineering & Architecture, Tokuyama College of Technology, Gakuendai, Japan<br />
2 Department of Civil & Environmental Engineering, Ehime University, Japan<br />
3 Department of Social & Environmental Engineering, Hiroshima University, Japan<br />
Many steel bridge infrastructures of the world are getting old and hence subjected to age-related<br />
deterioration such as corrosion wastage, fatigue cracking, or mechanical damage during their<br />
service life. These forms of damage can give rise to significant issues in terms of safety, health,<br />
environment, and life cycle costs. Since it is not possible to retrofit or rebuild those aged bridges<br />
at the same time, it is necessary to develop advanced technologies which can be used to assist<br />
proper maintenance of highway and railway infrastructures and evaluate the remaining strength<br />
capacities of those bridges, in order to keep them in-service until they required necessary retrofit<br />
or rebuild in appropriate time.<br />
This paper describes a simple method to estimate the remaining yield and tensile strength of<br />
corroded steel members by using a concept of representative effective thickness (t eff ) with the<br />
correlation of initial thickness (t 0 ) and the maximum corroded depth (t c ,max), based on the results<br />
of many tensile coupon tests of corroded plates obtained from a steel plate girder used for about<br />
100 years with severe corrosion.<br />
1.0 Introduction<br />
Corrosion is a time-based process of deterioration of a material as a result of a reaction with its environment. In this<br />
electrochemical process, initial attack occurs at anodic areas on the surface, where ferrous ions go into solution.<br />
Electrons are released from the anode and move through the metallic structure to the adjacent cathodic sites on the<br />
surface, where they combine with oxygen and water to form hydroxyl ions. These react with the ferrous ions from<br />
the anode to produce ferrous hydroxide, which itself is further oxidized in air to produce hydrated ferric oxide (i.e.<br />
red rust). The sum of these reactions can be represented by the following equation:<br />
4Fe + 30 2<br />
+ 2H 2<br />
0 = 2Fe 2<br />
0 3<br />
.H 2<br />
0 (1)<br />
(Steel) + (Oxygen) + (Water) = Hydrated ferric oxide (Rust)<br />
This process requires the simultaneous presence of water and oxygen. In the absence of either, corrosion does<br />
not occur. The consequences of corrosion are many and varied and the effects of these on the safe, reliable and<br />
efficient operation of structures are often considered than simply losing a volume of metal. One of the major harmful<br />
effects of corrosion is the reduction of metal thickness leading to loss of mechanical strength and structural failure,<br />
causing severe disastrous and hazardous injuries to people.<br />
There are more than 50,000 steel railway bridges in Japan, where more than half of them have been used over<br />
60 years and some bridges are aged over 100 years (Sugimoto, 2006). With aging, Corrosion becomes one of the<br />
major causes of deterioration of steel bridges, and its’ damages seriously affect on the durability of steel bridges<br />
(Fujii 2003 and Rahgozar, 2009).<br />
Recently, there are many damage examples reported due to corrosion and fatigue around the world. Though it’s a<br />
maintenance issue, it can be addressed appropriately by specification of a proper corrosion system in the design<br />
phase. It has been proved that the corrosion played a significant role in the catastrophic collapse of both the Silver<br />
Bridge (Point Pleasant, WV) in 1967 and the Mianus River Bridge (Connecticut) in 1983, USA (Steel Bridge Design<br />
Handbook). Those collapses indicated the paramount importance of attention to the condition of older bridges,<br />
leading to intensified inspection protocols and numerous eventual retrofits or replacements. Therefore corrosion is<br />
not an issue to be taken lightly either in design phase or in maintenance stage. Further, as some recent earthquakes<br />
demonstrated the potential seismic vulnerability of some types of steel bridges (Bruneau, 1997 and Zahrai, 2003),<br />
it would be very important to understand the behaviour of existing steel bridges which are corroding for decades, in<br />
future severe seismic events as well.<br />
To assure adequate safety and determine the ongoing maintenance requirements, thorough regular inspections<br />
are required. These inspections should form the essential source of information for carrying out a comprehensive<br />
evaluation of its current capacity. The accurate estimation of remaining strength of steel members will give the<br />
necessary information on establishing the performance recovery methods and necessary retrofitting techniques<br />
or replacements of severe corroded members. Therefore, establishment of more accurate remaining strength<br />
estimation method will be the core part in all maintenance tasks.<br />
It is known that the corrosion wastage and the stress concentration caused by the surface irregularity of the corroded<br />
steel plates influence the remaining strength of the corroded steel plates (Kariya, 2005). Therefore this study of the<br />
effect of different forms of corrosion on the remaining strength capacities of the existing structure is a vital task for<br />
the maintenance management of steel highway and railway infrastructures.<br />
Vol 24 No 3
<strong>AMMJ</strong><br />
Effective Thickness of Corroded Steel Plates 39<br />
2.0 Problem Statement<br />
Some researchers have done some experimental studies and detailed investigations of the corroded surfaces<br />
to introduce methods for estimating the remaining strength capacities of corroded tensile steel plates. Namely,<br />
Matsumoto et al. (1989) investigated the tensile strength, using tensile coupons with corrosion and predict the<br />
remaining tensile strength of the corroded plates, using the minimum value of average thickness (t sa ) of the cross<br />
section perpendicular to the loading axis as a representative thickness. Further, Muranaka et al. (1998) and Kariya<br />
et al. (2003) proposed different representative thickness parameters with a correlation of average thickness (t avg )<br />
<br />
and standard deviation of thickness ( st), to estimate the tensile strength of corroded members based on te<br />
many _ y <br />
tensile tests.<br />
<br />
Thus, it is very clear that, many researchers usually use representative thickness based on several statistical<br />
parameters to estimate the remaining strength. The all above described representative thickness concepts were<br />
derived with relation to the average thickness of the corroded plate (t avg ) which eventually depends on the accuracy<br />
of the thickness measurements. But, it is not easy to conduct bridge inspections with detailed investigations for each<br />
and every structure in regular basis as the number of steel bridge infrastructures in the world is steadily increasing<br />
as a result of building new steel structures and extending the life of older structures. Therefore, it is important to<br />
establish a simple and accurate procedure to predict the remaining strength capacities of a corroded steel member<br />
by measuring lesser number of points with an acceptable accuracy level. So, the objective of this paper is to present<br />
a remaining strength estimation method by using a representative effective thickness which is related with an easily<br />
measurable dimension like initial thickness (t 0 ), minimum thickness (t min ), etc.<br />
3.0 Experimental Investigation<br />
3.1 Measurement of Corroded Surface<br />
Py<br />
<br />
( yn / y ) ( bn / b ) yn y t eff = t 0 + (1-) t min () <br />
B<br />
y <br />
In this study, 42 specimens (21 each from web and flange) cut out from a girder of Ananai River in Kochi Prefecture<br />
on the shoreline of the Pacific Ocean, which had been used for about hundred years. It was constructed as a railway<br />
bridge in 1900, and in 1975 changed to a pedestrian bridge, when the reinforced concrete slab was cast on main<br />
girders. The bridge was dismantled due to serious corrosion damage in year 2001. Further, four corrosion-free<br />
specimens were cut down smoothly from both sides of corroded steel plate also fabricated in order to clarify the<br />
material properties. The JIS No.5 test specimen is shown in Figure 1.<br />
<br />
Figure 1<br />
JIS No. 5 Specimen for tensile test<br />
Before conducting the thickness measurements, the<br />
rust and paint on the surface were removed by using<br />
a steel wire brush and then applying high pressure<br />
water carefully in order to not change the condition<br />
of the corrosion irregularity. Then the thicknesses of<br />
all scratched specimens were measured by using<br />
a laser displacement gauge and the intervals of<br />
measurement data are 1mm and 0.3 mm in X and Y<br />
directions respectively. The measurement performed<br />
shaded area (70mm x 25mm) is shown in Figure<br />
1 and the condition of thickness measurement is<br />
shown in Figure 2. Then, the statistical parameters<br />
such as average thickness (t avg ), minimum thickness<br />
(t min ), standard deviation ( st ) and coefficient<br />
of variability (CV) were calculated from the<br />
measurement results.<br />
3.2 Outline of Tensile Test<br />
Py<br />
<br />
( yn / y ) ( bn / b ) yn y t eff = t 0 + (1-) t min () te<br />
_ y <br />
By<br />
<br />
The extensometer which can be used to measure<br />
elongation until maximum load was set between two<br />
marked points as shown in Figure 3 for all 42<br />
Figure 2<br />
Condition of thickness measurement<br />
Vol 24 No 3<br />
te _ b
<strong>AMMJ</strong><br />
Effective Thickness of Corroded Steel Plates 40<br />
Table 1: Material properties<br />
Table 1: Material properties<br />
Specimen<br />
Elastic<br />
modulus<br />
/(GPa)<br />
Poisson’s<br />
ratio<br />
Yield<br />
stress<br />
/(MPa)<br />
Tensile<br />
strength<br />
/(MPa)<br />
Elongation at<br />
maximum<br />
load /(%)<br />
Elongation<br />
after<br />
breaking<br />
/(%)<br />
Corrosion-free plate (flange) 198.9 0.272 308.7 418.7 19.28 40.12<br />
Corrosion-free plate (web) 192.7 0.284 291.1 415.4 20.82 39.65<br />
SS400 JIS 200.0 0.300 245~ 400~510 21.00 –<br />
corroded specimens and the yield strength, tensile<br />
strength and elongation were obtained from the<br />
load-elongation curves. The tensile test was<br />
performed very carefully at the loading velocities<br />
of 0.2 mm/min at elastic region and 0.5 mm/min at<br />
plastic region.<br />
First, the tensile test was performed for the four<br />
corrosion-free specimens (each two from flange<br />
and web) cut down smoothly from both sides of<br />
corroded steel plate.<br />
The fundamental mechanical properties of the<br />
material, such as elastic modulus, Poisson’s ratio,<br />
yield stress, tensile strength and the elongation<br />
were obtained as shown in Table 1. The standard<br />
values by JIS are also indicated in the table as the<br />
reference. It can be seen that these specimens<br />
have the equality with the SS400 Japanese<br />
Industrial Standards. And also the web and flange<br />
have almost the same properties.<br />
Then, the tensile tests were carried out for all<br />
flange and web specimens in order to clarify the<br />
relationship between the representative effective<br />
thickness which was used to estimate the remaining<br />
mechanical strength properties of the corroded<br />
plate and the degree of the corrosion state.<br />
3.3 Classification of Corrosion Levels<br />
Various types of corrosion conditions in actual steel<br />
structures can be seen as the corrosion damage<br />
can take place in many shapes and forms. But, it<br />
would be important to categorize those different<br />
corrosion conditions to few general types for better<br />
understanding of their remaining<br />
strength capacities considering their<br />
visual distinctiveness and the features<br />
of histograms, amount of corrosion<br />
and their expected mechanical and<br />
ultimate behaviors.<br />
Here, it is important that these<br />
corrosion levels could easily identified<br />
through few thickness measurements<br />
at the site and they represent not only<br />
the amount of corrosion, but also the<br />
remaining strength capacities for a<br />
brisk assessment of condition of the<br />
structure.<br />
Nominal Ultimate Stress Ratio, ( bn / b )<br />
1<br />
0.8<br />
0.6<br />
Figure 3<br />
Figure 4: Relationship of ultimate stress ratio & minimum thickness ratio ()<br />
0.4<br />
0.2<br />
Experimental set up of the corroded specimen<br />
Level I (Minor Corrosion)<br />
Level II (Moderate Corrosion)<br />
Level III (Severe Corrosion)<br />
The Figure 4 shows the relationship<br />
Severe<br />
Moderate<br />
Minor<br />
between the nominal ultimate stress<br />
Py<br />
Pb<br />
<br />
( yn ratio / y ) ( bn / b ) & yn the y minimum t eff = t 0 thickness + (1-) t min () te<br />
_ y <br />
0 te<br />
_ b<br />
0.25 0.5 Py0.75 1<br />
b<br />
ratio ( ), where bn (is yn / the y ) nominal ( bn / b ) yn y t eff<br />
= Bt <br />
P<br />
y<br />
0 + Py<br />
<br />
<br />
(1-) t min<br />
B() b<br />
Pb<br />
<br />
( yn / y ) ( bn / b ) yn y t eff = t 0 + (1-) t min () te<br />
_ y te<br />
_ b te<br />
_ y te<br />
_ b <br />
ultimate stress and b is (the yn /ultimate<br />
y ) ( bn / b ) yn y t eff = t 0 + (1-) t min () , (t min / 0 )<br />
B<br />
y<br />
B<br />
<br />
P<br />
y <br />
<br />
B b<br />
<br />
te<br />
_ y y B<br />
b<br />
P<br />
b <br />
<br />
te<br />
_ b <br />
stress of corrosion-free plate.<br />
By<br />
B b<br />
<br />
Figure 4 Relationship of ultimate stress ratio & minimum thickness ratio ( ) ( yn /<br />
Vol 24 No 3
Frequency, (%)<br />
Effective Thickness 41<br />
<strong>AMMJ</strong><br />
Severe of Corroded Corrosion Steel Plates ; < 0.5<br />
tmin<br />
Here, the minimum thickness ratio ( ) is defined as: <br />
Py<br />
<br />
( yn / y ) ( bn / b ) yn y t eff = t 0 + (1-) (2) t min () te<br />
_ y <br />
t0<br />
By<br />
<br />
In this study, three different types of corrosion levels were introduced according to their severity of corrosion, and<br />
which can be used for reliable remaining strength estimation ( bn of / b actual ) corroded steel structures. They are;<br />
Py<br />
<br />
Minor Corrosion ; > 0.75 ( yn / y ) ( bn / b ) yn y t eff = t 0 + (1-) t min () te<br />
_ y <br />
bn<br />
By<br />
Py<br />
<br />
Moderate Corrosion ; 0.75 ≥ ≥ 0.5 ( yn / y ) ( bn / b ) yn y t eff = t 0 + (1-) t min () te<br />
_ y <br />
Py<br />
<br />
By<br />
<br />
Severe Corrosion ; < 0.5( yn / y ) ( bn / b ) yn y t eff = t 0 + (1-) t min () te<br />
_ y te<br />
By<br />
<br />
Further, the following Figure 5 shows the thickness histograms of three members which are classified in to the above<br />
mentioned corrosion categories. There, the significance of these three corrosion categories can be recognized from<br />
the features of those thickness histograms as well.<br />
Usually in minor corrosion members, many tiny corrosion pits (less than 3mm depth) can be seen through out the<br />
specimen. Figure 5(a) shows that the peak of thickness histogram is almost the same as its average thickness for<br />
the minor corrosion type members. Further, it can be seen that the distribution width of the thickness histogram is<br />
very narrow.<br />
In moderate corrosion type members, though there are few considerable corroded pits (depth of 3-5 mm) exist<br />
in some places, many non-corroded portions also remain widely. Further, as it can be seen from Figure 5(b), the<br />
thickness distribution is larger than that of the minor corrosion members and the peak of thickness histogram is not<br />
the same as the average thickness of the member.<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
Average thickness (t avg ) : 9.40 mm<br />
Standard deviation ( st ) : 0.11 mm<br />
Minimum thickness (t min ) : 8.68 mm<br />
Minimum thickness ratio (<br />
(a)<br />
0 2 4 6 8 10<br />
Thickness [mm]<br />
Figure 5<br />
When the corrosion is more progressed, severe corrosion type can be seen with several extensive corroded regions<br />
(maximum corrosion depth over 5mm and the diameter of the corroded pits are exceeding 25mm) on the member.<br />
Usually in severe corroded members, few peaks of the thickness histogram can be seen as shown in Figure 5(c),<br />
and the highest peak is widely different from the average thickness as well.<br />
So, it is clear that the average thickness could not be able to use for the strength estimations of members with<br />
moderate or severe corrosion conditions.<br />
100<br />
3.4 Experimental Results<br />
Load-elongation curves for three different corroded<br />
specimens and one corrosion-free plate are shown in 80<br />
Figure 6.<br />
FT-22 and FT-18 have comparatively larger minimum<br />
Py<br />
<br />
thickness ratio ( = 0.827 ( yn /and y ) (0.632 bn / b ) respectively) yn y t eff = tand 0 + (1-) the t min () te<br />
_ y <br />
specimen FT-15 has comparatively lesser value of it ( =<br />
60 By<br />
<br />
0.469). Further it can be seen that the steel plate FT-5,<br />
in which the corrosion progression was more severe, the<br />
minimum thickness ratio is also diminutive ( =0. 231). 40<br />
Herein, the specimen (FT-22) with minor corrosion has<br />
almost the same mechanical properties (such as apparent<br />
yield strength and load-elongation behavior etc.) as the<br />
20<br />
corrosion-free specimen (FM-5).<br />
On the other hand, the moderately corroded specimen<br />
(FT-18) and the severe corroded (in this case, locally)<br />
specimen (FT-15) show obscure yield strength (Figure<br />
6). And the elongation of the specimen FT-15 decreases<br />
significantly. The reason for this is believed to be that the<br />
local section with a small cross-sectional area yields<br />
Frequency, (%)<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
Average thickness (t avg ) : 9.01 mm<br />
Standard deviation ( st ) : 0.60 mm<br />
Minimum thickness (t min ) : 6.64 mm<br />
Minimum thickness ratio (<br />
(b)<br />
Minor Corrosion ; > 0.75<br />
Moderate Corrosion ; 0.75 0.5<br />
0 2 4 6 8 10<br />
Thickness [mm]<br />
Frequency, (%)<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
Average thickness (t avg ) : 7.77 mm<br />
Standard deviation ( st ) : 0.97 mm<br />
Minimum thickness (t min ) : 4.92 mm<br />
Minimum thickness ratio (<br />
(c)<br />
0 2 4 6 8 10<br />
Thickness [mm]<br />
Thickness histigrams of (a) Minor corrosion type FT-22, (b) Moderate corrosion type (FT-18)<br />
and (c) Sever corrosion type (FT-15)<br />
Load (kN)<br />
Py<br />
<br />
( yn / y ) ( bn / b ) yn y t eff = t 0 + (1-) t min () te<br />
_ y <br />
By<br />
<br />
FM-5 (Corrosion-free plate)<br />
FT-22 (Minor Corrosion)<br />
FT-18 (Moderate Corrosion)<br />
FT-15 (Severe Corrosion)<br />
0 5 10 15 20<br />
Elongation, (%)<br />
Figure 6<br />
Load - elongation curves<br />
t<br />
_ b<br />
Vol 24 No 3<br />
e<br />
Pb<br />
<br />
<br />
B b<br />
<br />
Pb<br />
<br />
te<br />
_ b <br />
B b<br />
( yn / y ) ( bn / b ) yn y t eff = t 0 + (1-) t min Py<br />
<br />
() te<br />
_ y <br />
By<br />
<br />
t<br />
e<br />
_ b<br />
te _ b<br />
_ b<br />
te<br />
<br />
<br />
Pb<br />
<br />
<br />
B b
Effective Thickness of Corroded Steel Plates<br />
42<br />
<strong>AMMJ</strong><br />
at an early load stage because of the<br />
stress concentration due to irregularity<br />
of corroded steel plate. And this will<br />
lead the moderate and severe corrosion<br />
members to elongate locally and reach<br />
to the breaking point.<br />
Further, it was noted that the most of<br />
the corroded specimens had been<br />
broken either in a section of minimum<br />
thickness (t min ) or near the smallest<br />
average thickness (t sa ). Therefore, the<br />
local statistical parameters with the<br />
influence of stress concentration should<br />
be used for the yield and tensile strength<br />
estimations.<br />
Even though 42 specimens were tested<br />
in this study some of the specimens<br />
were broken outside the gauge length.<br />
Therefore only the successful specimens<br />
were considered for this research study<br />
& their corroded surface measurements,<br />
experimental yield and tensile loads<br />
and corrosion level classification are<br />
shown in Table 2. There, the initial<br />
thickness(t 0 ) of the flange specimens<br />
and web specimens are 10.5mm and<br />
10.0 mm respectively.<br />
Table 2 Measurement, experimental results and categorization of specimens<br />
Table 2: Measurement, experimental results and categorization of specimens<br />
Member<br />
t avg<br />
t min<br />
t sa<br />
st<br />
Experimental<br />
<br />
Corrosion<br />
/(mm)<br />
/(mm)<br />
/(mm)<br />
/(mm)<br />
Results<br />
P y /(kN)<br />
P b /(kN)<br />
(t min/t 0)<br />
Type<br />
FT-1 9.25 7.90 9.03 0.21 60.89 92.20 0.752 Minor<br />
FT-2 9.86 9.04 9.73 0.21 67.82 96.08 0.861 Minor<br />
FT-5 7.54 2.43 4.10 2.01 26.78 35.82 0.231 Severe<br />
FT-6 9.25 6.90 8.69 0.56 59.57 87.19 0.657 Moderate<br />
FT-8 9.16 8.47 9.02 0.20 64.10 91.39 0.807 Minor<br />
FT-9 9.39 8.34 9.16 0.26 62.32 91.04 0.794 Minor<br />
FT-10 9.03 8.29 8.88 0.21 65.75 91.24 0.790 Minor<br />
FT-11 8.97 7.50 8.41 0.47 61.88 87.42 0.714 Moderate<br />
FT-12 8.73 8.00 8.51 0.18 64.83 91.29 0.762 Minor<br />
FT-13 8.76 7.93 8.50 0.27 61.40 89.92 0.755 Minor<br />
FT-14 8.82 7.97 8.53 0.23 62.50 89.52 0.759 Minor<br />
FT-15 7.77 4.92 6.50 0.97 47.09 63.64 0.469 Severe<br />
FT-18 9.01 6.64 7.72 0.60 59.85 83.64 0.632 Moderate<br />
FT-22 9.40 8.68 9.25 0.11 67.75 93.96 0.827 Minor<br />
WT-1 9.26 8.42 8.89 0.22 63.91 89.54 0.842 Minor<br />
WT-2 9.41 8.31 8.96 0.37 65.45 90.53 0.831 Minor<br />
WT-3 9.46 8.07 9.24 0.27 65.41 91.38 0.807 Minor<br />
WT-4 9.26 8.35 9.00 0.20 64.46 92.00 0.835 Minor<br />
WT-5 9.16 7.88 8.71 0.31 62.87 91.21 0.788 Minor<br />
WT-6 9.48 8.55 9.22 0.22 64.75 91.68 0.855 Minor<br />
WT-7 9.32 7.86 9.04 0.43 64.23 87.19 0.786 Minor<br />
WT-8 9.27 7.92 8.89 0.25 64.78 91.19 0.792 Minor<br />
WT-9 9.09 8.11 8.87 0.29 61.30 87.00 0.811 Minor<br />
WT-11 9.31 8.13 8.90 0.25 63.24 90.96 0.813 Minor<br />
WT-12 9.31 8.47 9.00 0.18 64.15 92.72 0.847 Minor<br />
WT-13 8.82 7.61 8.33 0.29 63.74 90.78 0.761 Minor<br />
WT-15 9.22 8.14 9.01 0.24 61.86 88.71 0.814 Minor<br />
WT-16 9.02 8.14 8.79 0.24 62.78 89.36 0.814 Minor<br />
WT-17 9.13 8.18 8.94 0.24 62.16 90.03 0.818 Minor<br />
WT-18 9.17 8.20 8.94 0.16 65.23 92.03 0.820 Minor<br />
WT-19 8.86 7.70 8.49 0.38 63.46 87.41 0.770 Minor<br />
WT-21 9.16 8.03 8.89 0.19 69.64 91.03 0.803 Minor<br />
4.0 Residual Strength Estimation<br />
4.1 Estimation of Yield and Tensile Strength<br />
Py<br />
<br />
te<br />
_ y <br />
The two basic definitions can be expressed for the experimentally predicted parameters By<br />
for the yield effective<br />
thickness (t e_y ) and the tensile effective thickness (t e_b ) as follows:<br />
Py<br />
(3) b<br />
t<br />
P (4)<br />
e _ y <br />
te<br />
_ b <br />
By<br />
<br />
B b<br />
<br />
Where, P y : yield load, P b : tensile load, B: width of the specimen for the corroded state and y and ( yn /b y are )( yn ( yield / bn y / ) and b )( bn yn / b ) y yn t<br />
tensile stress of corrosion-free plate Pb<br />
respectively.<br />
te<br />
_ b <br />
But the above defined effective B thickness b parameters cannot be obtained for the in-service structures. So, a<br />
measurable statistical parameter with a high correlation with the effective thickness parameter will be essential for<br />
remaining strength estimation of those structures. Therefore, the correlations between the effective thickness (t eff )<br />
and measureable statistical parameters (such as average thickness t avg , minimum thickness<br />
Pt min , standard deviation<br />
y Pb<br />
<br />
of thickness st etc.) ( yn / were y ) examined ( bn / b ) and yn a y better t eff relationship = t 0 + (1-) was t min found () with the teminimum _ y thickness. Hence, te<br />
_ b in this <br />
study, a representative effective thickness (t eff ) based on the initial thickness (t 0 ) and the Bminimum y<br />
thickness (t B min )<br />
b <br />
was introduced as a new trial. So the aim is to use minimum thickness as the only variable parameter to represent<br />
the condition of corrosion in the process of estimating remaining strength capacities.<br />
Py<br />
<br />
The x-axis of Figure 7 is the minimum thickness ratio ( ) and (the yn / y ) y-axis ( bn /shows b ) yn the y t eff nominal = t 0 + (1-) stress t min ratio () normalized t e _ y te<br />
P<br />
y P<br />
y <br />
BP<br />
<br />
by<br />
by yield stress ( P<br />
b <br />
yn/ ( y yn ) / in ( y Figure yn ) /( y ) bn 7(a) / ( b bn ) and / b yn ) tensile yn y stress t eff y = t eff t ( 0 = + bn/ t ( (1-) 0 yn + b) / (1-) ( in t y min ) yn Figure /( t y min ) bn () / 7(b) ( b )() bn / respectively. yn b t) e _ y y yn t<br />
e _ t y<br />
eff y Figures = t eff t 0 = + t 7(a) (1-) 0 + teand _(1-) tb<br />
min t<br />
7(b) e _ bt min () ()<br />
t shows a good linear relationship between the minimum thickness ratio in both yield and tensile B<br />
By<br />
stress y<br />
conditions. B <br />
Bb<br />
b<br />
<br />
Also it is noted that an average unique relationship for both yield and tensile stress conditions can be obtained.<br />
From this relationship, a formula for representative effective thickness (t eff ) can be obtained as described below.<br />
From Figure 7(a),<br />
<br />
yn yn<br />
<br />
0.204<br />
<br />
0.795<br />
<br />
yy<br />
t eff = 0.204t 0 + 0.795t min (5)<br />
t<br />
In same way from Figure 7(b), eff<br />
t eff = 0.204t 00 + 0.795t min min<br />
t eff = 0.185t 0 0.839tmin (6)<br />
t<br />
So, a generalized equation for the eff<br />
t eff = 0.185t representative 00 + 0.839t effective min min<br />
thickness parameter, which satisfies the non corrosion<br />
condition, where, t min is equal to t 0 and the value of t eff should be equal to t 0 as well, can be expressed as:<br />
t eff<br />
t eff = t t 00 + (1-) t min<br />
t min<br />
(7)<br />
t eff<br />
t eff = 0.2 0.2 t 0<br />
t 0 + 0.8 0.8 t min<br />
t min<br />
Vol 24 No 3
Effective Thickness of Corroded Steel Plates<br />
43<br />
<strong>AMMJ</strong><br />
1<br />
1<br />
0.8<br />
0.8<br />
( yn / y )<br />
0.6<br />
0.4<br />
Y = 0.204 + 0.795 X<br />
R 2 = 0.911<br />
( bn / b )<br />
0.6<br />
0.4<br />
Y = 0.185 + 0.839 X<br />
R 2 = 0.943<br />
0.2<br />
0.2<br />
0 0.2 0.4 0.6 0.8 1<br />
, (t min / t 0 )<br />
0 0.2 0.4 0.6 0.8 1<br />
, (t min / t 0 )<br />
Figure 7 Relationship of (a) yield stress ratio, (b) tensile stress ratio and minimum thickness ratio ( )<br />
<br />
Considering both yield and tensile stress conditions, it was found that the λ =0.2 gives the best agreement and<br />
hence the representative effective thickness parameter can be defined as:<br />
t eff = 0.2 t 0 + 0.8 t min (8)<br />
Now, the maximum corroded depth (t c,max ) can be expressed as:<br />
t c,max = t 0 - t min (9)<br />
So, considering Eq. 8 and Eq. 9, the following relationship can be obtained for representative effective thickness<br />
(t eff ), which can be used to estimate the remaining yield and tensile strengths of a corroded steel plate.<br />
t eff = t 0 - 0.8 t c,max (10)<br />
A further detailed study comprises with experimental and numerical analysis of more specimens with moderate and<br />
severe corrosion is deemed necessary to understand the significance of this λ value and verify this for different<br />
corrosion levels and environmental conditions.<br />
10<br />
10<br />
( yn / y ) ( bn / b ) <br />
8<br />
(a) Matsumoto et al. 1989<br />
8<br />
(b) Muranaka et al. 1998<br />
t Matsumoto<br />
6<br />
4<br />
t Muranaka<br />
6<br />
4<br />
2<br />
2<br />
Coefficient of Correlation: R 2 = 0.88<br />
0 2 4 6 8 10<br />
t e_b<br />
10<br />
Coefficient of Correlation: R 2 = 0.04<br />
0 2 4 6 8 10<br />
t e_b<br />
10<br />
8<br />
(c) Kariya et al. 2003<br />
8<br />
(d) Proposed<br />
t Kariya<br />
6<br />
4<br />
t eff (Proposed)<br />
6<br />
4<br />
2<br />
Coefficient of Correlation: R 2 = 0.81<br />
2<br />
Coefficient of Correlation: R 2 = 0.90<br />
0 2 4 6 8 10<br />
0 2 4 6 8 10<br />
t e_b<br />
t e_b<br />
Figure 8 Relation between different predicted effective thickness parameters with te_b<br />
Vol 24 No 3
Effective Thickness of Corroded Steel Plates<br />
44<br />
<strong>AMMJ</strong><br />
4.2 Comparison of Proposed Effective Thickness<br />
The experimentally predicted thickness (Eq. 3 and Eq. 4) and the representative thickness which were valued<br />
by different methods were examined and compared to understand the effectiveness of the proposed method of<br />
estimating the remaining strength capacities of corroded steel plates. The following Figure 8 shows the behavior of<br />
representative thickness, valued by different methods and the experimental tensile effective thickness (t e_b ).<br />
Figure 8 shows that the strength estimations obtained by the effective thickness values proposed by all Matsumoto<br />
et al 1989, Muranaka et al 1998 and Kariya et al 2003 are rather overestimated. So, this could lead the corroded<br />
structures to be at risk as their actual remaining capacities are lesser than that of the predicted. But, the “Proposed”<br />
method is much closer to the actual conditions.<br />
The Table 3 shows the coefficient<br />
of correlation values of the<br />
available different methods and<br />
the proposed method of effective<br />
thickness in estimating remaining<br />
yield and tensile strengths. It<br />
clearly shows that the proposed<br />
effective thickness parameter<br />
gives more reliable and better<br />
prediction with the experimentally<br />
analyzed results than other<br />
available methods.<br />
5.0 Conclusions<br />
The 42 specimens taken out of the scrapped plate girder which had been used for about 100 years with severe<br />
corrosion, was used to perform the tensile tests to clarify the relationship between the representative effective<br />
thickness (t eff ) to estimate the mechanical properties of corroded plates and their level of corrosion. A representative<br />
effective thickness equation derived by using initial thickness and maximum corroded thickness (derived with<br />
minimum thickness) to estimate their remaining yield and tensile strengths is discussed from those experimental<br />
results.<br />
The main conclusions are as follows:<br />
1. The corrosion causes strength reduction of steel plates and minimum thickness ratio ( ) can ( yn be / y ) used ( bn /as b ) a<br />
yn y t eff =<br />
measure of the level of corrosion and their strength degradation. Therefore, three basic corrosion P categories can be<br />
y Pb<br />
<br />
<br />
defined, Minor Corrosion ( > 0.75), ( yn /Moderate y ) ( bn b ) Corrosion yn y t eff = (0.75 t 0 + ≥ (1-) ≥ t min 0.5) ( yn () and / y ) Severe (t<br />
bn e _/ y b ) Corrosion yn y t eff = ( t < 0.5) according<br />
B<br />
to their severity of corrosion.<br />
e t _<br />
b 0 + (1-) ( yn / t min y ) ( () bn / b ) t<br />
e yn _ y <br />
y t<br />
y<br />
B b<br />
B<br />
2. A representative effective thickness (t eff ), based on the initial thickness (t 0 ) and maximum corroded thickness<br />
(t c,max ) can be used to estimate the remaining yield and tensile strength of corroded steel plates. In estimation of<br />
both remaining yield strength and tensile strength, the proposed relationship revealed a good comparison with the<br />
experimental results and the derived equation is as follows:<br />
t eff = t 0 - 0.8 t c,max<br />
As the proposed effective thickness equation has only a single variable, maximum corroded thickness (t c,max ), which<br />
is an easily measurable parameter and the value of initial thickness (t 0 ) is a well known parameter, it will reduce the<br />
contribution of errors occurring during the practical investigation of a corroded member. Also it is necessary to note<br />
that the t max should be applied for very old bridges in which t 0 may not be known in very rare situations. Further this<br />
method is simple and gives more reliable and closer results compared to the other available methods.<br />
References<br />
Table Table 3: Comparison 3 Comparison of correlation of correlation coefficients coefficients of different of representative different representative<br />
thickness prediction<br />
methods<br />
thickness prediction methods<br />
Method<br />
Matsumoto<br />
et al. 1989<br />
Muranaka<br />
et al. 1998<br />
Kariya<br />
et al. 2003<br />
Proposed,<br />
Equation of thickness t sa t avg – 0.7 st t avg – 1.3 st t 0 - 0.8 t c,max<br />
Correlation<br />
Yield - - - 0.89<br />
Coefficient Tensile 0.88 0.04 0.81 0.90<br />
[1] A. Kariya, K. Tagaya, T. Kaita and K. Fuji [2003], ‘Basic study on effective thickness of corroded steel plate and<br />
material property’, Annual conference of JSCE, pp 967-968. (In Japanese)<br />
[2] A. Kariya, K. Tagaya, T. Kaita and K. Fuji [2005], ‘Mechanical properties of corroded steel plate under tensile<br />
force’, Proceedings of the 3rd International Structural Engineering and Construction Conference (ISEC-03), Japan,<br />
pp 105-110.<br />
[3] A. Muranaka, O. Minata and K. Fujii [1998], ‘Estimation of residual strength and surface irregularity of the<br />
corroded steel plates’, Journal of Structural Engineering, vol. 44A, pp 1063-1071 (In Japanese).<br />
[4] ‘Corrosion Protection of Steel Bridges’, Steel Bridge Design Handbook, Chapter 23, National Steel Bridge<br />
Alliance.<br />
[5] I. Sugimoto, Y. Kobayashi and A. Ichikawa [2006], ‘Durability Evaluation Based on Buckling Characteristics of<br />
Corroded Steel Deck Girders’, QR of RTRI, Vol. 47, No.3, pp 150-155.<br />
[6] K. Fuji, T. Kaita, H. Nakamura and M. Okumura [2003], ‘A Model Generating Surface Irregularities of Corroded<br />
Steel Plate for Analysis of Remaining Strength in Bridge Maintenance’, The 9th East Asia-Pacific Conference on<br />
Structural Engineering and Construction (EASEC-9), Vol. 9, pp 32-38.<br />
[7] M. Bruneau and S.M. Zahrai [1997], ‘Effect of Severe Corrosion on Cyclic Ductility of Steel’, Journal of Structural<br />
Engineering, Vol. 123, No.11 pp 1478-1486.<br />
t eff<br />
Vol 24 No 3
<strong>AMMJ</strong><br />
45<br />
[8] M. Matsumoto, Y. Shirai, I. Nakamura and N. Shiraishi [1989], ‘A Proposal of effective Thickness Estimation<br />
Method of Corroded Steel Member’, Bridge Foundation Engineering, Vol. 23, No. 12, pp 19-25. (In Japanese)<br />
[9] R. Rahgozar [2009], ‘Remaining Capacity Assessment of Corrosion Damaged Beams using Minimum Curves’,<br />
Journal of Constructional Steel Research, Vol. 65, pp 299-307.<br />
[10] S.M. Zahrai [2003], ‘Cyclic Strength and Ductility of Rusted Steel Members’, Asian Journal of Civil Engineering,<br />
Vol. 4, Nos. 2-4, pp 135-148.<br />
[11] T. Kaita, K. Tagaya, K. Fuji, M. Miyashita and M. Uenoya [2005], ‘A simple estimation method of bending<br />
strength for corroded plate girder’, Proceedings of the 3rd International Structural Engineering and Construction<br />
Conference (ISEC-03), Japan, pp 89-97.<br />
Spares Criticality Has Many Dimensions<br />
Phillip Slater Materials and Spare Parts Management Specialist (Australia)<br />
One of the things that most maintenance and reliability groups struggle with is the issue of spare parts criticality.<br />
It seems that criticality is often seen as a single dimension issue, that is, an item either is, or isn’t, critical. But<br />
I don’t think that is right. I think spare parts criticality is a multi-dimensional issue.<br />
What do I mean by multi-dimensional? Not that criticality exists in some science fiction space-time continuum<br />
but rather that it has a number of characteristics that need to be considered before deciding what to hold in<br />
inventory.<br />
For example, is the item in question machine critical or operationally critical? By machine critical I mean, will<br />
failure of the item stop the piece of equipment of which it is a part? By operationally critical, I mean, will failure<br />
of the item stop production? These two characteristics are quiet different and have a different impact on what<br />
to do next.<br />
For example, the globe in a headlight on my car is machine critical to the light. Obviously, the light will not work<br />
without the globe. But my car will still operate. In fact, in daylight hours there is no noticeable difference. If<br />
the globe fails at night I would notice the difference but would still be able to operate the car until I can get the<br />
globe replaced. Yes, safety will be slightly reduced but I think that this is, in this specific case, acceptable for<br />
a short period.<br />
Compare the globe failure with a fan belt failure. If you break a fan belt you won’t be able to drive for more<br />
than a few minutes before the vehicle starts to overheat and be un-drivable. The fan belt is not only machine<br />
critical it is also operationally critical. Yet, how many people carry spare fan belts for their cars? Not many.<br />
Why: because the failure is rare and the result may be inconvenient but in most cases tolerable (catch a taxi,<br />
get the car towed, call the auto club etc.). If you live in a city you are unlikely to carry a fan belt. If you live in<br />
or are driving through a remote area you probably would carry a fan belt. The decision (and quantity to hold)<br />
is dependent upon the situation.<br />
What about brakes. Everyone would agree that brakes are pretty important but who carries spare brake pads?<br />
No-one. Why: because inspections will identify pad wear so that you replace the pads before they become<br />
dangerous (plus the occasional grinding noise is a bit of a giveaway!) Everyone would argue that brake pads<br />
are operationally critical, but no-one would carry brake pads.<br />
Here we have three items. Each is machine critical, two are operationally critical, yet none are carried as spares,<br />
except in specific (for most of us unusual) circumstance. Spare parts criticality is definitely multi-dimensional<br />
and the inventory that we hold should be a function of the situation. For some critical spare parts we can still<br />
operate until we get the spare, for some we can wait until the spare arrives, for some we can manage through<br />
condition monitoring.<br />
Of course there are some items that we just can’t live without. Just don’t think that all items identified as critical<br />
will fall into that final category.<br />
Phillip Slater is a leading authority on materials and spare parts management and is currently celebrating ten<br />
years as an independent consultant, where he has assisted 297 companies, with more than 1,000 storerooms,<br />
holding $3.5bn in inventory. He is also the author of four operations management books, including Smart<br />
Inventory Solutions, now in its second edition and a recent finalist in the RGVA 2011 book awards. For more<br />
information on spare parts management visit Phillip’s website www.PhillipSlater.com.<br />
Vol 24 No 3
Total Productive Maintenance -<br />
20 Years On In The UK<br />
Roy Davis MCP Consulting and Training UK<br />
It is now a little over 20 years since TPM made its debut in the UK and this article takes the opportunity<br />
to look back at the original introduction of TPM to the western world and in particular UK industry and<br />
to try and assess how it has progressed, evolved, succeeded and failed during the period.<br />
Background<br />
The significant event that bought Total Productive Maintenance<br />
to the notice of industrialist and academics within the UK was<br />
the publication of Seiichi Nakajima’s book ‘Introduction to TPM’<br />
that was translated into English and published by Productivity<br />
Press in 1988.<br />
Although the concepts of TPM had been developed in Japan<br />
from as early as 1971, the publication of Nakajima’s book was<br />
the first that people within the UK had heard about TPM. In fact,<br />
the book was not published in Japan until 1984.<br />
The emergence of TPM coincided with the major influx of<br />
Japanese manufacturing philosophies and approaches of the<br />
late 1980’s and early 1990’s that threatened to spark a revolution<br />
in the way in which manufacturing businesses were configured<br />
and operated. The introduction of Just in Time, Kan Ban, Total<br />
Quality, Cellular Manufacturing, Single Piece Flow, Poka Yoke<br />
Devices, Single Minute Exchange of Die and problem solving<br />
tools such as Taguchi Design of Experiments, Ishikawa Diagrams, Quality Function Deployment, etc. were at the<br />
time quite overwhelming for us Westerners especially as were also at the time grappling with the requirements of<br />
Statistical Process Control and the move from quality control to quality assurance. For all of us involved in change<br />
management within our factories, this was a very challenging but exciting period.<br />
My first glimpse of TPM was a brochure advertising a training course that was to be provided by the publishers of<br />
Nakajima’s book at a venue in Manchester which I decided to attend as my brief at the time was to ‘improve the<br />
way in which we go about maintenance’ for the multi-national manufacturing company for which I worked at that<br />
time. I attended the course and although the presenters did not appear to be experienced TPM implementers,<br />
the explanation of the basic principles and philosophy behind TPM made me realise that this was something very<br />
different from the rest of the maintenance approaches and techniques that I had hitherto studied.<br />
My interest in TPM gradually increased, particularly as I became project manager of a major DTI sponsored<br />
maintenance improvements project (Maintenance Systems for Modern Manufacturing Businesses) and I was<br />
fortunate enough to attend what I believe was one of the first TPM based study tours of Japan which took place in<br />
1991 and included attendance at the TPM World Congress in Tokyo which had been organised by the Japan Institute<br />
of Plant Maintenance (JIPM). Through listening to the papers presented (many of which were not actually related to<br />
TPM but other maintenance approaches) and especially visiting demonstrator sites in and around Tokyo and Kyoto,<br />
& discussion with my fellow industrialists taking part in the tour, our understanding of TPM began to gel.<br />
Once we had returned to the UK, myself and a number of my fellow travellers, worked within our own organisations<br />
to try and introduce and establish TPM within our factories. A ‘TPM Club’ was set up under the auspices of the<br />
Institution of Mechanical Engineers and a committee was formed which included ‘TPM minded’ people from across<br />
a wide range of industry, training and consultancy organisations. Visits were arranged to UK and European sites<br />
that were starting to implement TPM and seminars were organised, some featuring prominent Japanese speakers<br />
who were associated with the (JIPM) including Professor Yamashina<br />
The Five Pillars of TPM<br />
It is important to remind ourselves of the basic principles and philosophy of TPM which is as relevant now as it was<br />
20 years ago and is encapsulated by the original ‘Five Pillars of TPM’ i.e.<br />
• Maximize Overall Equipment Effectiveness (it is implied that we are measuring OEE)<br />
• Establish a thorough system of preventive maintenance for the equipment’s entire life span<br />
• Implement TPM by involving all departments (e.g. Engineering, Operations, maintenance)<br />
Measure and Maximise OEE<br />
The 5 Pillars of TPM<br />
Establish a system of PM<br />
New Systems<br />
and Procedures<br />
Involve all Departments<br />
Involve all Employees<br />
Promote TPM Through SGA<br />
Cultural Change:<br />
Involvement, Motivation,<br />
Behaviour<br />
Minimum 3 years implementation<br />
Vol 24 No 3
<strong>AMMJ</strong><br />
TPM - 20 Years On In The UK 47<br />
• Involve every single employee, from top management to workers on the floor<br />
• Promote TPM through motivation management: autonomous small group activities (1)<br />
The original book suggested a 3 year programme for TPM implementation.<br />
Where are we Now?<br />
The UK TPM Time Line<br />
A glance at the list of the JIPM, TPM prize winners<br />
for the last 2 years seems to indicate that there<br />
are very few examples of UK companies that have<br />
implemented and sustained a comprehensive<br />
TPM programme (with the notable exception of<br />
Tetrapak and Unilever). The situation may be<br />
slightly distorted by the fact that JIPM awards<br />
are usually only awarded to companies that have<br />
used their consultancy services either directly<br />
or via one of their approved partners. This<br />
does however, bear out my own perception that<br />
although TPM was extremely popular in the early<br />
to mid 1990’s, very few UK organisations had the<br />
determination or support to introduce and then<br />
sustain a long term TPM programme.<br />
There have been some positive influences as a<br />
result of UK industry’s exposure to TPM over the<br />
years though, for example:<br />
1980’s 1990’s 2000’s<br />
2010’s<br />
TPM Awareness &<br />
Awakening of Interest<br />
TPM development,<br />
pilot applications<br />
TPM becomes very<br />
popular, many companies<br />
try to implement<br />
Some successes, many<br />
failures, TPM becomes<br />
less popular<br />
• Overall Equipment Effectiveness (OEE) is now used an important Key performance Indicator (KPI)<br />
by many manufacturing businesses<br />
• The use of OEE (whether it is calculated correctly or not) has provided more focus on the major<br />
losses encountered within manufacturing areas<br />
• Small group activity involving production operators and maintenance personnel has increased and<br />
although they are not always referred to as autonomous TPM teams, in many cases, that is exactly<br />
what they are<br />
• There is much more emphasis on workplace organisation and cleanliness in many companies<br />
who run 5S or CAN DO (2) activities and carry out regular shop floor based audits and improvement<br />
activities<br />
• The recording and analysis of downtime information (usually as a part of the OEE measurements)<br />
has helped companies to identify the contribution to operational performance that good maintenance<br />
practice can make.<br />
• Some Operator Asset Care programmes do encapsulate many of the good principles of Autonomous<br />
Maintenance, especially when they are not just seen as a means of moving Technician jobs to<br />
operators but also as a means of engaging Production Operators in continuous improvement<br />
activities and developing ownership of their facilities<br />
• TPM is a familiar acronym these days, most people working within manufacturing have heard of<br />
TPM, although I would question whether many really understand its core philosophy and principles.<br />
Conclusion<br />
Returning to the original 5 pillars of TPM it is true to say that the first two that are related to OEE and PM systems<br />
have been the least difficult to implement and that is why many manufacturing businesses have embraced these<br />
pillars.<br />
The other three pillars relate to people issues including involvement, motivation, changing behaviour and overall<br />
culture change are much more difficult and take longer to implement. That is why TPM programmes take many<br />
years to bring about change and so it should not be surprising that these have not been either attempted or if<br />
attempted, sustained in many companies as in general, Senior and Middle managers do not have the will, the longer<br />
term vision or the determination to make TPM succeed.<br />
References:<br />
1. An Introduction to TPM, Total Productive Maintenance. Seiichi Nakajima – Productivity Press<br />
2. Productivity Improvements Through TPM. Roy Davis – Prentice Hall<br />
OEE, 5S’s, OAC, SGA very<br />
common, Total TPM system<br />
very rare<br />
Roy Davis, MCP Consulting and Training rdavis@mcpeurope.com<br />
(First Published in the M&E Magazine Vol10 No6)<br />
Vol 24 No 3
<strong>AMMJ</strong> - Maintenance Books<br />
Asset Management and Maintenance Journal’s Book List<br />
Prices are valid until 30th September 2011. All prices are Australian Dollars. Prices for Australia Include Postage and GST.<br />
Prices for the rest of the World add the following shipping charges: One book add Aus$40; Each additional book add Aus$25.<br />
1. Engineering Asset Management Review<br />
(Eds) Amadi-Echendu, Brown, Willett, Mathew.<br />
2011 394pp $260<br />
Engineering Asset Management Review (EAMR) is<br />
published under the auspices of the International<br />
Society of Engineering Asset Management<br />
(ISEAM). Engineering Asset Management focuses<br />
on life-cycle management of the physical assets<br />
required by a private or public firm, for the purpose<br />
of making products, and/or for providing services<br />
in a manner that satisfies various business performance rationales.<br />
In exploring the wide ranging issues involved in the management of<br />
engineered assets constituting our built environment, EAMR takes a<br />
broad view of the inter- and multi-disciplinary approach which combines<br />
science, engineering, and technology principles with human behavior<br />
and business practice.<br />
2. Reliability Maintainability and Risk 8th Edition<br />
David Smith<br />
2011 352pp $145<br />
Practical Safety-Related Systems Engineering<br />
Methods:<br />
This book provides engineers with the safety and<br />
risk assessment tools and techniques they need<br />
to work effectively in any safety or reliability critical<br />
environment. These tools are primarily statistical.<br />
Where David Smith’s book succeeds is by meeting<br />
the needs of an applied audience by setting these<br />
tools in the context of the design and operation of safety related<br />
processes and systems. Now in its Eighth Edition, this is regarded<br />
as the core reference in this field, and the success of its approach is<br />
reflected in the popularity of this standard work.<br />
It deals with all aspects of reliability, safety-related systems, and the<br />
assessment and management of risk in a simple and straightforward<br />
way, pre-supposing no prior knowledge and dealing simply and<br />
realistically with numerical data by using the minimum of mathematical<br />
and technical jargon.<br />
3. Complete Guide to Predictive and<br />
Preventive Maintenance 2nd Edition<br />
Joel Levitt<br />
2011 250pp $95<br />
This book shares the best practices, mistakes,<br />
victories, and essential steps for success which the<br />
author has gleaned from working with countless<br />
organizations. Unlike other books that only focus<br />
on the engineering issues (task lists) or management issues (CMMS),<br />
this in-depth resource is the first to give true emphasize to the four<br />
aspects of success in preventive maintenance systems--engineering,<br />
management, economic, and psychological -- thereby enabling readers<br />
to have a balanced view and understanding of what is happening in<br />
their organizations. Additionally, it blends concrete actionable steps<br />
and structures with the theory behind the steps.<br />
• Includes check sheets, history of PM, stories, photographs, and<br />
case histories.<br />
• Contains a glossary of terms.<br />
• Provides sample task lists for a variety of equipment with some of<br />
the logic behind each task.<br />
• Offers templates for developing your own tasking.<br />
• Includes protocols for detailed economic analysis with examples.<br />
4. Design for Reliability<br />
Daniel T. Daley<br />
2011 238pp $85<br />
None of the few Design for Reliability (DFR) books currently available<br />
addresses the process from the owner’s (or buyer’s) perspective.<br />
Instead, they approach DFR strictly from the seller’s (or manufacturer’s)<br />
viewpoint. As a result, few assets are designed and developed with the<br />
intent to meet the future owner’s specific needs for<br />
reliability, availability, and maintainability over the<br />
life of the asset. In this groundbreaking new book,<br />
Dan Daley intends to correct the imbalance in how<br />
DFR is often implemented by providing owners with<br />
the tools they need to ensure that their requirements<br />
(not the seller’s) are followed in developing new<br />
assets. This book will be an invaluable guide to<br />
everyone involved in the design, development, or<br />
purchase of new assets. It will help owners take the<br />
necessary steps to get what they really need, and it will help sellers<br />
“deliver the goods” that their customers (the owners ) actually want.<br />
• Explains how to properly integrate DFR activities with conventional<br />
design activities.<br />
• Provides a simple system to ensure DFR activities are completed<br />
on time.<br />
• Provides spreadsheets and forms needed to portray design results<br />
in a clear and usable format.<br />
• Includes the tables and forms needed to support the design<br />
processes and procedures presented in each chapter.<br />
• Includes appendices that provide an example specification that<br />
owners can modify when procuring a new asset and example tables<br />
useful in assessing how well the DFR process has met the owner’s<br />
needs.<br />
5. Physical Asset Management<br />
Nicholas A J Hastings<br />
2010 370pp $345<br />
Physical asset management is the management<br />
of fixed or non-current assets such as equipment<br />
and plant. Physical Asset Management presents a<br />
systematic approach to the management of these<br />
assets from concept to disposal.<br />
Historically, asset management has not been<br />
seen as a specific professional activity, but now perceptions are<br />
changing. Many organizations are introducing senior positions in<br />
asset management, and universities are introducing courses in asset<br />
management at graduate and advanced undergraduate level. The broad<br />
reach of this book means that it will be applicable to professionals and<br />
future professionals across a wide variety of industries, ranging from<br />
manufacturing and distribution, to local government.<br />
Physical Asset Management addresses the needs of existing and<br />
potential asset managers, and provides an introduction to asset<br />
management for professionals in related disciplines, such as finance.<br />
The book provides both an introduction and a convenient reference<br />
work, covering all the main areas of physical asset management.<br />
6. Asset Data Integrity Is Serious Business<br />
Robert DiStefano and Stephen Thomas<br />
2010 224pp $90<br />
If your asset data is not reliable, you need to<br />
convince the organization of the enormous<br />
potential that is locked away. To accomplish this,<br />
you need to understand the breadth of the problem<br />
and the value of solving it. A viable business case<br />
for action is needed-so let’s get started!<br />
Physical asset data integrity is a critical aspect of<br />
every business, often the most valuable asset on<br />
the balance sheet, yet it is often overlooked. The<br />
data that we have about our assets collectively creates information,<br />
provides for accurate analysis and facilitates sound business decisions.<br />
Without accuracy of asset data there is a strong potential for poor<br />
decisions and their negative consequences. This book will not only<br />
provide an appreciation of this fact, it will also provide a road map to<br />
achieving value out of something most CEOs, managers, and workers<br />
often overlook.<br />
• Relies on the authors’ decades of experience and hands-on expertise<br />
that cannot be obtained elsewhere.<br />
• Includes an assessment tool enabling the reader to easily recognize<br />
areas of improvement once a problem is detected.<br />
Vol 24 No 3
• Features a valuable practical “how to” information.<br />
• Focuses on the entire management spectrum, allowing everyone<br />
to see the value of data integrity within the context of their own<br />
responsibilities.<br />
7. E-Maintenance<br />
Holmberg, K.; Adgar, A.; Arnaiz, A.;<br />
Jantunen, E.; Mascolo, J.; Mekid, S. (Eds.)<br />
2010 511pp $260<br />
E-maintenance is the synthesis of two major<br />
trends in today’s society: the growing importance<br />
of maintenance as a key technology and the rapid<br />
development of information and communication<br />
technology. E-maintenance gives the reader an<br />
overview of the possibilities offered by new and<br />
advanced information and communication technology to achieve<br />
efficient maintenance solutions in industry, energy production and<br />
transportation, thereby supporting sustainable development in society.<br />
Sixteen chapters cover a range of different technologies, such as: • new<br />
micro sensors; • on-line lubrication sensors; • smart tags for condition<br />
monitoring; • wireless communication; and • smart personal digital<br />
assistants. E-maintenance also discusses semantic data-structuring<br />
solutions; ontology structured communications; implementation of<br />
diagnostics and prognostics; and maintenance decision support by<br />
economic optimisation. It includes four industrial cases that are both<br />
described and analysed in detail, with an outline of a global application<br />
solution. E-maintenance is a useful tool for engineers and technicians<br />
who wish to develop e-maintenance in industrial sites. It is also a<br />
source of new and stimulating ideas for researchers looking to make<br />
the next step towards sustainable development.<br />
8. Benchmarking Best Practices 2nd Edition<br />
Terry Wireman<br />
2010 256pp $90<br />
Thoroughly revised and updated, this best selling book<br />
presents a logical, step-by-step methodology that<br />
will enable any company to conduct a cost-effective<br />
benchmarking effort. It presents an overview of the<br />
benchmarking process, a detailed form for surveying<br />
and “grading” maintenance management, and a<br />
database of the results of more than 100 companies that have used<br />
this survey.<br />
• Provides a clear, concise benchmarking methodology.<br />
• Clearly explains and interprets the most current maintenance<br />
benchmarks.<br />
• Benchmarking database from more than 100 companies.<br />
• Features current maintenance/asset management philosophies.<br />
• Offers more information on self-analysis.<br />
9. Maintenance Planning, Coordination & Scheduling<br />
Don Nyman and Joel Levitt<br />
2010 300pp $85<br />
Based on real-world experience this invaluable guide<br />
and reference tells the whole story of maintenance<br />
planning from beginning to end in a concise and<br />
easy-to-follow manner. Written by well-known<br />
professionals this new edition focuses specifically<br />
on the preparatory tasks that lead to effective<br />
utilization and application of maintenance resources<br />
in the interest of the reliability essential to business<br />
objectives. It comprehensively examines the job<br />
preparation process from job scoping and planning,<br />
to determination of material requirements, estimation of labor<br />
requirements and job duration, coordination of all involved parties,<br />
and job scheduling. And it includes essential metrics for measuring<br />
performance of all contributing functions. It is a vital training document<br />
for planners, an educational document for those to whom planners<br />
are responsible, and a valuable guide for those who interface with the<br />
planning and scheduling function and are dependent upon the many<br />
contributions of planning and scheduling operational excellence.<br />
• Expanded coverage of the proactive culture and environment tha<br />
senior management must nurture throughout the organization,<br />
and the essential supportive roles of other functions essential to the<br />
preparatory process.<br />
• A new chapter that enumerates prerequisites to effective Planning,<br />
Coordination and Scheduling.<br />
• The Scheduling chapter has been expanded to include a debate<br />
comparing two popular approaches to the scheduling & achievement<br />
of Schedule Compliance.<br />
• The Material Support chapter is significantly expanded.<br />
10. Smart Inventory Solutions<br />
Phillip Slater<br />
2010 180pp $70<br />
Smart Inventory Solutions is the result of the<br />
author’s time spent working with clients and studying<br />
the issues people face in trying to achieve their<br />
inventory reduction. This landmark manual shows<br />
you the seven Actions for Inventory Reduction so<br />
you can easily, efficiently and sustainably achieve<br />
your inventory reduction, free up cash, and reduce your costs without<br />
risk and impact on your capability. Additionally, it shows you the<br />
author’s self-developed Inventory cash release process to follow,<br />
the mistakes to avoid and a sure fire approach that minimizes your<br />
workload. In fact you’ll learn how to generate better results for these<br />
types of inventory.<br />
Features<br />
• Shows you how to eliminate 100% excess of inventory and reduce<br />
inventory related working capital by up to 40%.<br />
• Illustrates how to reduce your ongoing inventory management<br />
costs.<br />
• Helps you develop the skills of your team to enable ongoing inventory<br />
management and independence.<br />
• Provides 20 exclusive case studies and real life examples.<br />
• Can be applied to all ‘bought in’ inventories such as parts and<br />
components, finished goods, OEM spares, MRO inventory<br />
engineering spares, and industrial supplies.<br />
• Includes a data collection guide.<br />
11. All-In-One Manual of Piping Practice<br />
and Maintenance<br />
K.K.Murty<br />
2010 384pp $95<br />
Books on design of pipelines, and equipment such<br />
as pumps and compressors are available but almost<br />
none on the piping that carries fluid to and fro. This<br />
practical, no-frills book offers complete coverage<br />
of piping practices and maintenance all in one place. Written by a<br />
professional with 35 years of hands-on knowledge and experience in<br />
pipeline building, operating, and maintenance, this manual is designed<br />
to be kept at the ready, on the shop floor. Maintenance engineers and<br />
managers will wonder how they’ve survived so long without it!<br />
• Features practical insight and valuable notes.<br />
• Uses charts and spec sheets wherever necessary instead of<br />
calculations and formulas.<br />
• Provides problems, precautions, and troubleshooting tips.<br />
• Extensive use of photos enables users to understand what they<br />
need to know.<br />
12. TPM Reloaded<br />
Joel Levitt<br />
2010 223pp $70<br />
This is a challenging, innovative, and timely new<br />
look at implementing Total Productive Maintenance<br />
(TPM) by one of the field’s leading trainers and<br />
authors. The book takes into account the economic<br />
upheavals of recent years and demonstrates that<br />
TPM is less about moving maintenance tasks to<br />
operations than moving accountability for aggregate output of the plant<br />
to operators. The author goes on to show that effective TPM - TPM<br />
reloaded -- requires a radical difference in management’s view of the<br />
worker and even tougher, a radical change in the way workers view<br />
their own role.<br />
13. Handbook of Maintenance Management<br />
and Engineering<br />
Ben-Daya; Duffuaa; Raouf;<br />
KnezevicJ; Ait-Kadi. (Eds.)<br />
2009 741pp $445<br />
This handbook covers a wide range of topics in<br />
maintenance management and engineering. It<br />
includes extensive references to the theoretical<br />
foundations, recent research and future directions<br />
of this important subject.<br />
Using applications and examples which reflect the growing importance<br />
of maintenance, this book presents readers with an inter-disciplinary<br />
perspective on topical issues which affect any organization engaged<br />
Vol 24 No 3<br />
49
in manufacturing, process, or service industry, no matter how large<br />
or small. Contributors to the book are maintenance experts with<br />
both academic and industrial backgrounds, who are able to offer<br />
a comprehensive analysis of the subject matter, including both<br />
quantitative treatment and discussion of management issues.<br />
This handbook features both fundamental and applied works from<br />
across the whole maintenance spectrum. It will provide professionals<br />
with the solutions and management skills needed to evaluate and to<br />
continuously improve maintenance systems. This handbook will also<br />
be an invaluable resource for researchers and graduate students<br />
working in this area.<br />
14. Maintenance and Reliability Best<br />
Practices<br />
Ramesh Gulati and Ricky Smith<br />
2009 420pp $100<br />
To truly realize a best practice requires learning, relearning,<br />
benchmarking and implementing better<br />
ways of ensuring high reliability and availability of<br />
equipment and systems.<br />
Maintenance & Reliability Best Practices is designed to support<br />
that learning process. Written by professionals with 60 plus years<br />
of shop floor and management experience in a variety of industries,<br />
this practical resource will help seasoned professionals and novices<br />
understand the basic principles of maintenance and reliability. Written<br />
in an easy-to-read format, each chapter discusses the concepts with<br />
specific questions and answers. Each topic answers the what, why or<br />
how of the topic being presented. Understanding and implementing<br />
M&R practices in a cost-effective way is essential. This is the perfect<br />
book for all in the work force of an organization who need to have a solid<br />
understanding of M&R. Many years experience packed into one book.<br />
Useful to both the novice and seasoned professionals. Topics include<br />
Best Practices; Culture and Leadership; Understanding Maintenance;<br />
Work Management, Planning and Scheduling; Inventory Management;<br />
Measuring and Design for Reliability and Maintainability; Role of<br />
Operations; PM Optimization; Managing Performance; Workforce<br />
Management; M & R Analysis Tools,<br />
15. Handbook of Maintenance<br />
Management 2nd Edition<br />
Joel Levitt<br />
2009 455pp $110<br />
Now in its second edition and written by a highly<br />
acclaimed maintenance professional, this<br />
comprehensive and easy-to-understand resource<br />
provides a short review of all the major discussions<br />
going on in the management of the maintenance<br />
function. This revision of a classic has been thoroughly updated to<br />
include advances in technology and thinking and is sure to be found<br />
useful by maintenance professionals everywhere. It’s the perfect<br />
reference for any maintenance professional that needs a quick update<br />
on any specific area within the subject.<br />
• Contains five entirely new chapters, including Dealing with<br />
Contracts, 5S, Lean Maintenance, PM Optimizing, and Fire Fighting.<br />
• Offers a complete survey of the field, an introduction to maintenance<br />
and a review of maintenance management.<br />
* Provides a manual for cost reduction & a primer for the stockroom.<br />
• Includes a training regime for new supervisors, managers, planners.<br />
16. Mining Equipment Reliability,<br />
Maintainability and Safety<br />
Balbir S Dhillon<br />
2008 201pp $210<br />
The mining industry makes use of various types of<br />
complex and sophisticated equipment, for which<br />
reliability, maintainability and safety has become<br />
an important issue. Mining Equipment Reliability,<br />
Maintainability, and Safety is the first book to<br />
cover these three topics in a single volume.<br />
Mining Equipment Reliability, Maintainability, and Safety will be<br />
useful to a range of individuals from administrators and engineering<br />
professionals working in the mining industry to students, researchers<br />
and instructors in mining engineering, as well as design engineers<br />
and safety professionals. All topics covered in the book are treated<br />
in such a manner that the reader requires no previous knowledge to<br />
understand the contents. Examples, solutions and test problems are<br />
also included to aid reader comprehension.<br />
17. Maintenance Engineering<br />
Handbook 7 th Edition<br />
L.R. Higgins, K. Mobley and D.J. Wikoff<br />
2008 1200pp $290<br />
A valuable source of information for Maintenance<br />
Engineers, Managers, Plant Engineers, Supervisors<br />
and Maintenance technicians. The most<br />
comprehensive resource of its kind, Maintenance<br />
Engineering Handbook has long been a staple<br />
for engineers, managers, and technicians seeking current advice on<br />
everything from tools and techniques to planning and scheduling. This<br />
brand-new edition brings you up to date on the most pertinent aspects<br />
of identifying and repairing faulty equipment.<br />
Maintenance Engineering Handbook has been advising plant and<br />
facility professionals for more than 50 years. Whether you’re new<br />
to the profession or a practiced veteran, this updated edition is an<br />
absolute necessity.<br />
18. Corrosion Inspection and Monitoring<br />
Pierre R Roberge and R. Winston Revie<br />
2007 383pp $180<br />
The comprehensive reference on modern<br />
techniques and methods for monitoring and<br />
inspecting corrosion:<br />
• The impact of corrosion on the economy and the<br />
safe operation of systems in diverse operational<br />
environments<br />
• The various forms of corrosion, with a focus on the detectability of<br />
corrosion damage in the real world<br />
• The principles of risk-based inspection and various risk assessment<br />
methodologies (HAZOP, FMECA, FTA, and ETA), with examples<br />
from industry<br />
• The monitoring of microbiologically induced corrosion (MIC),<br />
cathodic protection (CP) systems, and atmospheric corrosion<br />
• Non-destructive evaluation (NDE) techniques, including visual,<br />
ultrasonic, radiogr., electromagnetic, & thermographic inspection<br />
• Roadmaps used by various industries and organizations for<br />
carrying out complex inspection and monitoring schedules<br />
19. Rules of Thumb for Maintenance &<br />
Reliability Engineers<br />
Ricky Smith and R Keith Mobley<br />
2007 336pp $160<br />
Rules of Thumb for Maintenance and Reliability<br />
Engineers will give the engineer the “have to<br />
have” information. It will help instill knowledge on<br />
a daily basis, to do his or her job and to maintain<br />
and assure reliable equipment to help reduce<br />
costs.<br />
This book will be an easy reference for engineers and managers<br />
needing immediate solutions to everyday problems. Most civil,<br />
mechanical, and electrical engineers will face issues relating to<br />
maintenance and reliability, at some point in their jobs. This will become<br />
their “go to” book. Not an oversized handbook or a theoretical treatise,<br />
but a handy collection of graphs, charts, calculations, tables, curves,<br />
and explanations, basic “rules of thumb” that any engineer working<br />
with equipment will need for basic maintenance and reliability of that<br />
equipment.<br />
20. Asset Management and<br />
Maintenance - The CD<br />
Nicholas A Hastings<br />
2007 Edition<br />
Over 2000 PPT slides $195<br />
50<br />
Asset Management and Asset Management<br />
Overview; Life Cycle Costing; Maintenance<br />
Organisation & Control; Spares & Consumables Management; Failure<br />
Mode and Effects Analysis; Risk Analysis and Risk Management;<br />
Reliability Data Analysis; Age Based Replacement Policy Analysis;<br />
Availability and Maintainability; Measuring Maintenance Effectiveness;<br />
Reliability of Systems; Condition Monitoring: Job and Shutdown<br />
Planning: Continuous Improvement: Financial Analysis: Forecasting:<br />
Budgeting and Planning: Strategic Asset Management: Team Plan<br />
Method: Cost benefit Analysis: Exercises: References: Form and<br />
Spreadsheet Templates .<br />
Vol 24 No 3
51<br />
MAINTENANCE STRATEGY<br />
SERIES<br />
Terry Wireman<br />
21.1 Preventive Maintenance (Vol 1)<br />
2007 220pp $90<br />
The first volume in this series, Preventive<br />
Maintenance, begins by detailing the importance of<br />
preventive maintenance to an overall maintenance<br />
strategy. The text clearly illustrates how the<br />
components of any maintenance strategy are<br />
interlinked with dependencies and the performance<br />
measures necessary to properly manage the preventive maintenance<br />
program. A process flow diagram details the steps of developing<br />
the preventive maintenance program, and the appendixes contain<br />
numerous examples of preventive maintenance inspections for the<br />
reader to begin applying to their program immediately.<br />
• Shows how to tactically develop a preventive maintenance program,<br />
answering questions, such as “What equipment to include?, What skill<br />
level of the technicians are required?, How to actually perform basic<br />
PM tasks?”, and many others.<br />
• Does not over-emphasize the value of preventive maintenance to<br />
the exclusion of other components of a maintenance strategy.<br />
21.2 MRO Inventory & Purchasing (Vol 2)<br />
2007 150pp $90<br />
The second volume in the series, Inventory and<br />
Purchasing, shows the reader how to develop<br />
an inventory and purchasing program for<br />
MRO spares and supplies as part of an overall<br />
strategy. Specifically, the text focuses on the<br />
importance of a well organized storage location<br />
and part inventory numbering system detailing<br />
to the reader the most effective ways to accomplish this goal.<br />
The receiving and parts issues disciplines are discussed in detail<br />
with a focus on the value proposition for spare parts controls and<br />
justification of storeroom overhead. In addition, the appendixes<br />
provide examples of parts and detail storage conditions that<br />
can be utilized in developing or refining an inventory storage<br />
location.<br />
21.3 Maintenance Work Management Processes (Vol 3)<br />
2007 200pp $90<br />
Work Management Processes, focuses on developing a work<br />
management process that will support the maintenance strategy<br />
components. It outlines a financially cost effective process that<br />
collects the data to use advanced strategies such as RCM and<br />
TPM. The text extensively details the maintenance organizational<br />
development process and then outlines nine basic work management<br />
flows. The nine flows are then detailed and the potential problems<br />
with executing the flows are examined along with solutions to the<br />
most common problems.<br />
• The Business of Maintenance<br />
• Work Identification Process<br />
• Emergency – Breakdown Work Process<br />
• Work Request Process<br />
• The Simple Planning Process<br />
• The Complex Planning Process<br />
• The Preventive Maintenance Process<br />
• Project Planning Process<br />
• The Weekly Scheduling Process<br />
• The Work Closure and Analysis Process<br />
21.4 Successfully Utilizing CMMS/EAM Systems (Vol 4)<br />
2008 238pp $90<br />
Shows how CMMS/EAM systems are necessary to support a<br />
maintenance and reliability organization in companies today. The<br />
proper methodologies for selecting and implementing a CMMS/EAM<br />
system. How to properly utilize the system to gain a maximum return<br />
on the system investment.The organization and methodology to truly<br />
achieve Enterprise Asset Management - an elusive goal for most<br />
organizations.<br />
Contents:<br />
• Introduction to CMMS/EAM<br />
• Maintenance Strategy Assessment<br />
• CMMS/EAM Systems<br />
• The Selection Process<br />
• The CMMS/EAM System Implementation Process<br />
• Utilization of the CMMS/EAM System<br />
• CMMS/EAM System Optimization<br />
• Return on Investment<br />
• The Future of CMMS/EAM Systems<br />
• Performance Indicators for CMMS/EAM Systems<br />
22. Facility Manager’s Maintenance<br />
Handbook 2 ND Edition<br />
B. Lewis and R Payant<br />
2007 560pp $240<br />
An essential on-the-job resource, Facility Manager’s<br />
Maintenance Handbook presents step-by-step<br />
coverage of the planning, design, and execution<br />
of operations and maintenance procedures for<br />
structures, equipment, and systems in any type of<br />
facility.<br />
This career-building reference provides the tools needed to streamline<br />
facility management processes?reduce operational costs?and ensure<br />
the effective utilization, maintenance, repair, and renovation of existing<br />
physical assets.<br />
Now with 40% new information, this Second Edition includes brand-new<br />
chapters on emergency response procedures, maintenance operations<br />
benchmarking,capital and operational budgets management, boiler<br />
and steam plant operations... and other vital topics.<br />
The only book of its kind to cover both operations and maintenance,<br />
the updated Facility Manager’s Maintenance Handbook features:<br />
• Updated information on mechanical equipment and systems<br />
maintenance<br />
• The latest fire protection procedures<br />
• A comprehensive account of building codes<br />
• Guidance on hazardous materials handling<br />
• Excellent preparation for the IFMA Certified Facility Manager (CFM)<br />
qualification<br />
23. Maintenance Planning &<br />
Scheduling Handbook 2nd Ed<br />
Richard D Palmer<br />
2006 544pp $180<br />
Many readers already regard the Maintenance<br />
Planning and Scheduling Handbook as the chief<br />
authority for establishing effective maintenance<br />
planning and scheduling in the real world. The<br />
second edition adds new sections and further<br />
develops many existing discussions to make the<br />
handbook more comprehensive and helpful.<br />
In addition to practical observations and tips on such topics as creating<br />
a weekly schedule, staging parts and tools, and daily scheduling, this<br />
second edition features a greatly expanded CMMS appendix which<br />
includes discussion of critical cautions for implementation, patches,<br />
major upgrades, testing, training, and interfaces with other company<br />
software. Readers will also find a timely appendix devoted to judging<br />
the potential benefits and risks of outsourcing plant work. A new<br />
appendix provides guidance on the “people side” of maintenance<br />
planning and work execution.<br />
The second edition also has added a detailed aids and barriers<br />
analysis that improves the appendix on setting up a planning group.<br />
The new edition also features “cause maps” illustrating problems with<br />
a priority systems and schedule compliance. These improvements<br />
and more continue to make the Maintenance Planning and Scheduling<br />
Handbook a maintenance classic.<br />
Vol 24 No 3
52<br />
PLANT MAINTENANCE<br />
MANAGEMENT SERIES<br />
Anthony Kelly<br />
3 Volume Set Price is $210<br />
24.1 Strategic Maintenance<br />
Planning (Vol 1)<br />
2006 304pp $105<br />
Strategic Maintenance Planning deals with<br />
the concepts, principles and techniques of<br />
preventive maintenance, and shows how<br />
the complexity of maintenance strategic<br />
planning can be resolved by a systematic<br />
`Top-Down-Bottom-Up? approach. It explains<br />
how to establish objectives for physical assets and maintenance<br />
resources, and how to formulate an appropriate life plan for<br />
plant. It then shows how to use the life plans to formulate a<br />
preventive maintenance schedule for the plant as a whole, along<br />
with a maintenance organization and a budget to ensure that<br />
maintenance work can be resourced. This is one of three standalone<br />
volumes designed to provide maintenance professionals<br />
in any sector with a better understanding of maintenance<br />
management, enabling the identification of problems and the<br />
delivery of effective solutions.<br />
24.2 Managing Maintenance Resources (Vol 2)<br />
2006 312pp $105<br />
Managing Maintenance Resources shows how to reduce<br />
the complexity involved in engineering, or re-engineering, a<br />
maintenance organization. It recognises that this is a complex<br />
problem involving many inter-related decisions – such as<br />
whether or not resources should be centralized,<br />
contractor alliances be entered into or flexible<br />
working be adopted. This book provides a<br />
unique approach to modeling maintenanceproduction<br />
organizations. It enables the<br />
identification of problems and delivers<br />
guidelines to develop effective solutions. This<br />
is one of three stand-alone volumes designed<br />
to provide maintenance professionals in<br />
any sector with a better understanding of<br />
maintenance management, enabling the identification of problems<br />
and the delivery of effective solutions.<br />
24.3 Maintenance Systems and<br />
Documentation (Vol 3)<br />
2006 264pp $105<br />
Managing Systems and Documentation<br />
addresses the main systems necessary for<br />
the successful operation of a maintenance<br />
organization, such as performance control, work<br />
control and documentation.<br />
It shows how they can be modelled, their<br />
function and operating principles, and the main<br />
problems encountered in operation. It is the third of three stand-alone<br />
companion books with the aim of providing better understanding of<br />
maintenance operations, in order to identify problems and prescribe<br />
effective solutions. This is one of three stand-alone volumes<br />
designed to provide maintenance professionals in any sector with<br />
a better understanding of maintenance management, enabling the<br />
identification of problems and the delivery of effective solutions.<br />
25. Maintenance Benchmarking & Best Practices<br />
Ralph W Peters<br />
2006 566pp $150<br />
Over the past decade, companies have<br />
redirected their maintenance operational focus<br />
from internal cost-cutting to profit-maximization.<br />
This approach is referred to as profit centered<br />
maintenance. Peters provides maintenance<br />
supervisors and managers with a benchmarking/<br />
best practices road-map called the Maintenance<br />
Operations Scoreboard. The Scoreboard will<br />
allow maintenance managers to: a) determine and quantify benefits<br />
and savings, b) improve craft productivity and c) define a strategy to<br />
improve efficiency and productivity. These things are at the heart of<br />
a successful Profit Centered Maintenance organization. The authordevised<br />
Maintenance Operations Scoreboard is used to perform<br />
over 200 maintenance evaluations in over 5,000 profit centered<br />
maintenance organizations. For example, at Honda of America,<br />
it was used extensively to direct maintenance strategy. It was later<br />
translated into Japanese for presentation to key Japanese executives.<br />
Another excellent example is Boeing Commercial Aircraft Inc. Over 60<br />
facility maintenance work units, at region, group and team levels, are<br />
evaluated at on-site visits using the Scoreboard criteria.<br />
26. Maximizing Machinery Uptime<br />
Heinze P Bloch and Fred K Geitner<br />
2006 672pp $180<br />
The authors use their decades of experience and<br />
draw upon real-world examples to demonstrate<br />
that the application of their techniques provides<br />
a basis for equipment management, uptime<br />
maximization, and reduced maintenance costs.<br />
The text explores reliability assessment techniques<br />
such as Failure Mode, Effect Analysis, and Fault Tree Analysis of<br />
commonly encountered rotating machinery. These are all highly<br />
effective techniques that the engineer can apply to maximize uptime<br />
and thereby maximize production and profitability.<br />
27. Improving Maintenance & Reliability<br />
Through Cultural Change<br />
Stephen J Thomas<br />
2005 356pp $90<br />
This unique and innovative book explains how<br />
to improve your maintenance and reliability<br />
performance at the plant level by changing the<br />
organizations culture. It is specifically intended for<br />
middle managers in the manufacturing and process<br />
industries. This book demystifies the concept of<br />
organizational culture and links it with the eight elements of change:<br />
leadership, work process, structure, group learning, technology,<br />
communication, interrelationships, and rewards. If you want to break<br />
the cycle of failed improvement programs and instead use cultural<br />
change to help make significant and lasting improvements in plant<br />
performance, this book will show you how.<br />
* Explains in-depth the eight elements of change and how they relate<br />
to cultural change.<br />
* Discusses cultural change with a reliability focus. Includes a<br />
PowerPoint presentation with audio on the enclosed CD-ROM, together<br />
with a web survey model, the Web of Organizational Change.<br />
28. Turnaround, Shutdown & Outage Management<br />
Tom Lenahan<br />
2005 256pp $110<br />
Shutdown management is project management<br />
of a special kind: managing the repair,<br />
replacement or maintenance of critical systems.<br />
Manufacturing and process plants, computer<br />
systems, airliners, and many other systems<br />
must be regularly closed down or taken out of<br />
service for planned maintenance operations.<br />
This book provides a complete shutdown project<br />
planning guide along with a new, detailed model<br />
of excellence and step-by-step project guide. In a critical field, this<br />
book shows the maintenance manager or project leader how to get<br />
the job done correctly.<br />
Vol 24 No 3
MAINTENANCE BOOKS – ORDER FORM<br />
Prices are valid until 30 September 2011. All prices are Australian Dollars. Prices for Australia Include Postage and GST.<br />
Prices for the rest of the World add the following shipping charges: One book add AUD$40; Each additional book add AUD$25<br />
Engineering Information Transfer P/L, 7 Drake Street, Mornington, Vic 3931 Australia<br />
Ph: 03 5975 0083 Fax: 03 5975 5735 Email: mail@maintenancejournal.com<br />
Item Book Title Quantity $<br />
1. Engineering Asset Management Review 260<br />
2. Reliability Maintainability and Risk 8th Edition 145<br />
3. Complete Guide to Predictive and Preventive Maintenance 2nd Edition 95<br />
4. Design for Reliability 85<br />
5. Physical Asset Management 345<br />
6. Asset Data Integrity Is Serious Business 90<br />
7. e- Maintenance 260<br />
8. Benchmarking Best Practices 2nd Edition 90<br />
9. Maintenance Planning, Coordination and Scheduling 85<br />
10. Smart Inventory Solutions 70<br />
11. All-in-One Manual of Piping Practice and Maintenance 95<br />
12. TPM Reloaded 70<br />
13. Handbook of Maintenance Management and Engineering 445<br />
14. Maintenance and Reliability Best Practices 100<br />
15. Handbook of Maintenance Management 2nd Edition 110<br />
16. Mining Equipment Reliability Maintainability and Safety 210<br />
17. Maintenance Engineering Handbook 7th Edition 290<br />
18. Corrosion Inspection and Monitoring 180<br />
19. Rules of Thumb for Maintenance and Reliability Engineers 160<br />
20. Asset Management and Maintenance - The CD (2000 PPT Slides) 195<br />
21.1 Maintenance Starategy Series Vol 1 - Preventive Maintenance 90<br />
21.2 Maintenance Starategy Series Vol 2 - MRO Inventory & Purchasing 90<br />
21.3 Maintenance Starategy Series Vol 3 - Maintenance Work Management Processes 90<br />
21.4 Maintenance Starategy Series Vol 4 - Successfully Utilizing CMMS/EAM Systems 90<br />
22. Facility Manager’s Maintenance Handbook 2nd Edition 240<br />
23. Maintenance Planning and Scheduling Handbook 2nd Edition 180<br />
24. Plant Maintenance Management Series 3 Volume Set 210<br />
24.1 Plant Maintenance Management Series Vol 1 - Strategic Maintenance Planning 105<br />
24.2 Plant Maintenance Management Series Vol 2 - Managing Maintenance Resources 105<br />
24.3 Plant Maintenance Management Series Vol 3 - Maintenance Systems and Documentation 105<br />
25. Maintenance Benchmarking and Best Practices 150<br />
26. Maximizing Machinery Uptime 180<br />
27. Improving Maintenance and Reliability Through Cultural Change 90<br />
28. Turnaround, Shutdown and Outage Management 110<br />
53<br />
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Vol 24 No 3
Maintenance News<br />
Effective collision avoidance technology from AIS<br />
Growing productivity of mining sites results in significant<br />
dependence on heavy vehicles and automated equipment in<br />
open cut and underground mines. Drivers of those massive<br />
vehicles struggle with limited visibility and especially in conditions<br />
of heavy dust and smoke. This moving machinery poses a real<br />
risk to life or damage through collisions.<br />
TAVOR is one of our best safety solutions for mining sites.<br />
Originally designed for military armoured vehicles, the system,<br />
manufactured by Opgal (Israel), is based on thermal imaging<br />
technology. It can be easily installed on heavy machinery and is<br />
created to work reliably in harsh operating conditions including<br />
strong shock and vibration, high temperature, rain and dust.<br />
This cost-effective thermal imaging kit has powerful and<br />
proprietary algorithms which enable driving in complete<br />
darkness. It enables seeing through smoke, dust and dirt; antiblooming<br />
mechanism prevents dazzle when pointed at high heat<br />
sources. AIS (Applied Infrared Sensing) web-site:<br />
www.applied-infrared.com.au<br />
SKF knowledge to create leadership in maintenance<br />
efficiency in Chinese heat and power generation<br />
“I selected SKF in order to make the Jiaxing New Jies plant one<br />
of the leaders and an industry standard in combined heating and<br />
power (CHP) generation, regarding maintenance efficiency”.<br />
This ambitious statement came from Mr. Ji Rong Lin, Executive<br />
General Manager, whose plant, in the Zhejiang province<br />
southwest of Shanghai, supplies approximately 112,000 KWh/<br />
hour of electricity into the national electricity grid and 400 tons/<br />
hour of steam for central heating to local community houses, as<br />
well as to a hospital, a government building and many factories,<br />
in a 15 km radius of the power plant.<br />
Maintenance efficiency is a relatively young science in many<br />
parts of the world and in many industries. China belongs to<br />
a large number of countries where opportunity is high, and<br />
ambition is high to reap the rewards that an experienced and<br />
professional approach can bring.<br />
Local Chinese companies active in maintenance services could<br />
provide some of the support that Mr Ji envisaged, but he felt<br />
there was more to be achieved. He wanted a partner that could<br />
handle the management objectives from a single perspective with<br />
regard to his total plant assets and a total advanced maintenance<br />
approach, and not in a series of separate and uncoordinated<br />
projects. In addition he wanted to engage a company using the<br />
very latest maintenance practices, from which his own personnel<br />
could learn, because part of his own business philosophy is<br />
to develop into a knowledge-based company with continuous<br />
improvement as a core activity.<br />
His search brought him in contact with Dr. Liang Dong, Asset<br />
Management Services Manager, SKF China, part of the worldwide<br />
SKF Group. Dr Dong had presented at a maintenance conference<br />
attended by one of Mr Ji’s senior managers. Impressed by the<br />
‘total and modern approach’ described in the SKF presentation,<br />
the manager set up a first meeting at the New Jies plant.<br />
“Directly after our first meeting I knew SKF could provide what<br />
we needed”, said Mr. Ji. “The scope of the proposal made by<br />
Dr. Dong covered all my areas of concern, and even some that<br />
were new to me. It was apparent that SKF had deep professional<br />
experience how to enter an organisation like mine and transform<br />
the entire maintenance philosophy from the traditional one,<br />
where long-serving people were the knowledge sources, into<br />
one where processes, new maintenance practices, benchmark<br />
comparisons, well documented data, knowledge sharing etc<br />
provide the basis for progress. Of course we have a good level<br />
of traditional time-based maintenance operations, but I want<br />
that level to be pushed continually higher! By working with SKF<br />
my people will get exposure to proven and applied advanced<br />
concepts and methodologies in the area of condition based<br />
maintenance, root cause failure analysis and reliability centered<br />
maintenance”.<br />
The scope of the project involves the setting up of a fully<br />
computerized Enterprise Asset Management system (EAM),<br />
setting up data gathering methods and routines, training and<br />
supporting the New Jies personnel in the use of the new system,<br />
reviewing and updating the maintenance strategy to improve<br />
work efficiency, defining damage and failure levels of all assets<br />
- especially critical items - defining spare parts and inventory<br />
needs, and developing Key Performance Indicators (KPIs).<br />
All machinery and equipment requiring maintenance, including<br />
linear assets such as steam transmission piping, will be identified<br />
and ‘tagged’ according to the Power Plant Industry standard<br />
KKS coding, and entered into a new computerized maintenance<br />
management system (CMMS). The electronic storing of data<br />
and the coding structure allows faster and consistent access and<br />
tracking of all maintainable plant assets and their maintenance<br />
history, by any authorized personnel at the New Jies plant.<br />
Compared to the current paper-based, manual system for storing<br />
and retrieving data this will increase tremendously the speed<br />
of maintenance operations and give much greater guarantee<br />
of always having the latest information available on any asset<br />
– which leads to better decision making regarding maintenance.<br />
And, faster and more efficient maintenance decisions and<br />
actions have a large and direct positive affect on the financial<br />
performance of all manufacturing and process industries,<br />
including Thermal Power.<br />
The project is run with very close cooperation between the SKF<br />
team and the New Jies maintenance team. Five SKF persons<br />
are involved in the project and, on average, 2-3 SKF persons<br />
are on-site every day. The close proximity of the SKF team and<br />
the New Jies team maintains the pace of progress and allows all<br />
questions and concerns to be immediately attended to. Weekly<br />
project reports from SKF keep everyone updated, and documents<br />
generated during the project are uploaded to a shared file server<br />
at the plant, for further detailed inspection, discussion or action.<br />
A monthly meeting covers all ‘progress against plan’ issues and<br />
looks into any aspect where mutual discussion is needed to<br />
decide the next steps.<br />
The project is running on schedule and Mr Ji said; “I am very<br />
happy with the progress so far. While it will take time before we<br />
can assess the effect of the new maintenance approach, I am<br />
convinced it will deliver everything we expect.<br />
As well as the range of results Mr Ji expects for his company<br />
in the short term he is looking ahead. His company plan to<br />
install two more boilers and another turbo-generator set that will<br />
increase annual capacity by 160 million KWh of electricity and<br />
500,000 tons of steam, and allow more of the local community to<br />
utilize the power plant output.<br />
“I am very keen to complete this maintenance project and<br />
see my people applying the new systems, methodologies and<br />
knowledge. That will deliver our short term goals but also put<br />
us in an excellent position to more efficiently operate the plant<br />
after our planned capacity expansion. By the time the added<br />
capacity is available everything will be in place, my people will be<br />
experienced and the whole transition to the larger maintenance<br />
demands will be offset by the increased level of professionalism<br />
and efficiency that my team will have built up. We will make even<br />
bigger nett savings due to their ability to apply the new approach<br />
to an increased output.<br />
www.skf.com<br />
Vol 24 No 3
Maintenance News 55<br />
1-Million Pounds award to new centre of excellence<br />
for asset maintenance to benefit many industries<br />
The Lloyd’s Register Educational Trust (The LRET) has awarded<br />
Holland’s University of Twente £1 million over the next five years<br />
to establish The LRET Maintenance Research and Education<br />
Programme, which will be at the core of the university’s new<br />
Centre of Excellence in Maintenance Engineering.<br />
Maintenance is a technical field which plays a key role in assuring<br />
the health of industry and public services such as transportation.<br />
The University of Twente estimates that there is as much as<br />
€400bn presently invested in public and private sector assets in<br />
The Netherlands alone, requiring €18bn to be spent each year<br />
on maintenance, and creating jobs for about 150,000 people.<br />
Funding from The LRET will be used to set up three elements of<br />
the programme: a Master of Science in Maintenance Engineering;<br />
an International Master of Science in Maintenance Management<br />
(involving two other Dutch universities, the Technical University<br />
of Eindhoven and the Technical University of Delft); and research<br />
on the fundamental principles of maintenance, which will be<br />
aligned with the post-graduate teaching programme.<br />
“Maintenance is a key discipline for anyone who aspires to<br />
deliver sustainable industrial services to society. To guarantee<br />
safe, clean, reliable and affordable operations, capital assets<br />
require state-of-the-art strategies for their maintenance, repair<br />
and overhaul. Those strategies increasingly underpin the<br />
effective identification and management of any risks to safety,<br />
health and the environment,” said Director of The LRET, Michael<br />
Franklin. “This sponsorship therefore fulfils our mission to<br />
support advances in transportation, science, engineering and<br />
technology-related education.”<br />
ABB acquires Mincom to expand enterprise<br />
software business<br />
ABB, the global power and automation technology group, has<br />
agreed to acquire Mincom to broaden its software portfolio and<br />
establish the Group as a leader in enterprise asset management<br />
(EAM) software and services.<br />
Mincom brings expertise and experience in a range of industries,<br />
and a comprehensive set of solutions for applications such as<br />
EAM, mining operations and mobile workforce management.<br />
Mincom has nearly 1,000 employees and annual revenues of<br />
approximately $200 million. With a distribution network in 19<br />
countries, the company is a leading software player in the Asia-<br />
Pacific and Latin America regions, with customers including 17<br />
of the top 20 global mining groups, as well as businesses in the<br />
energy sector, defense and other asset-intensive industries.<br />
“The acquisition of Mincom is part of our strategy to continuously<br />
broaden our software offering, “ said Joe Hogan, CEO of ABB.<br />
“Mincom helps us to increase the depth of our enterprise asset<br />
management offering, building our position as a leader in the<br />
key growth sectors of natural resources and energy. For our<br />
customers this means extending the life of their infrastructure,<br />
optimizing asset management and reducing the overall cost of<br />
ownership.”<br />
“Joining forces with ABB is a logical next step in the development<br />
of our company and a strong validation of the business, our<br />
people and our products,” said Greg Clark, CEO of Mincom. “It<br />
will expand our global reach and service capabilities, enabling<br />
us to continue building on the business we have fostered over<br />
the past three decades.”<br />
ABB is a leader in power and automation technologies. The<br />
ABB Group of companies operates in around 100 countries and<br />
employs about 124,000 people.<br />
www.abb.com<br />
New best-in-class T-Series models from FLIR.<br />
More choice for professional thermographers.<br />
Newly released T-Series models<br />
from FLIR Systems will result in<br />
greater choice for professional<br />
thermographers with T620/T640<br />
cameras boasting the highest<br />
307,200 (640 x 480) infrared<br />
pixel resolution available and<br />
a host of new features at an<br />
industry-leading price. These<br />
advanced models give expert<br />
thermographers the tools they<br />
need to work quickly, accurately, and efficiently in industrial,<br />
utility, heating, ventilation, and air conditioning (HVAC) and<br />
building diagnostics settings.<br />
The new leading-edge T-Series cameras combine high resolution<br />
imaging with flexible ergonomics, a large 4.3” touch-screen and<br />
viewfinder, Wi-Fi connectivity to iPhone® and iPad®, 8x digital<br />
zoom, a 5 MP visible light digital camera and all of the advanced<br />
analytics features FLIR’s professional customers have come to<br />
expect. FLIR has also given its T335/365 and T425 cameras new<br />
high infrared resolution options up to 76,800 pixels (320 x 240) for<br />
increased accuracy over greater distances. Among many other<br />
new features these cameras also now get Wi-Fi connectivity,<br />
3.5” touch-screen, advanced rotating lens ergonomics, P-i-P<br />
and thermal fusion overlays.<br />
“The release of these new T620/640-Series cameras<br />
demonstrates FLIR’s unwavering commitment to our customer<br />
base, where we continually provide the best technology, most<br />
innovative features, and quality cameras at an affordable<br />
price,” said FLIR Systems Australia Managing Director, Roger<br />
Christiansz.<br />
The new FLIR T640/620 cameras give professional<br />
thermographers the highest thermal resolution and sensitivity<br />
for the best-looking images and most accurate temperature<br />
measurements. Coupled with the 5 megapixel digital camera<br />
and LED lamp, you’ll get the sharpest visible light and thermal<br />
images you need to create the most effective documentation.<br />
See the results jump off the screen.The imagers offer 2%<br />
accuracy,
Maintenance News 56<br />
Mainpac partners with CIEAM to deliver better asset<br />
management software for mining & manufacturing<br />
Software developer Mainpac Pty Ltd has become the Australian<br />
software participant with the Australian Cooperative Research<br />
Centre for Infrastructure and Engineering Asset Management<br />
(CIEAM).<br />
The alliance will develop solutions aimed at improving the<br />
efficiency and sustainability of infrastructure and engineering<br />
asset management. These solutions will permit mining,<br />
manufacturing and other asset intensive industries to formulate<br />
long term strategies to optimise asset use and sustainability.<br />
Under the partnership the results of research conducted by CIEAM<br />
will find their way into future Mainpac software solutions.<br />
Research now underway will address the application of standards<br />
such as ISO 15926 and MIMOSA to provide interoperability of<br />
asset management information systems, a consistent asset<br />
management information auditing and assessment methodology,<br />
support for infrastructure management through the combination<br />
of sensors and asset information models and multi-criteria<br />
decision support systems.<br />
Mainpac chairman James Kirk, who with CIEAM chief executive<br />
officer Professor Joe Mathew, is driving the partnership<br />
arrangement, said the new Mainpac software will help enable<br />
asset management strategies so that company directors can<br />
achieve stronger financial and operational performance of their<br />
assets and consequently better corporate governance.<br />
Mainpac’s engagement is significant. With James Kirk now<br />
a CIEAM board member, the head of Mainpac’s development<br />
division in Adelaide, Michael Töns, has been appointed an<br />
industry advisor to CIEAM, as well as being on the Centre’s<br />
research committee.<br />
Mr.Töns is also project leader responsible for CIEAM’s input to a<br />
new suite of Mainpac software solutions which will be launched<br />
in <strong>July</strong>.<br />
www.mainpac.com.au<br />
TransGrid Adopts Mincom’s Next-Generation<br />
Solution for Enterprise Asset Management<br />
Mincom, a global provider of software solutions and services for<br />
asset-intensive industries, has announced a significant new deal<br />
worth $7.2 million with TransGrid, one of the largest high-voltage<br />
electricity transmission network operators in Australia.<br />
Under the agreement, TransGrid will implement Mincom Ellipse<br />
8, a comprehensive and modern Enterprise Asset Management<br />
(EAM) solution for asset-intensive industries, as well as<br />
Mincom applications for human resources and supply chain<br />
management.<br />
The organisation will also deploy the Mincom Mobility suite of<br />
integrated field-enablement applications, including Mincom<br />
Mobile Worker and Mincom Mobile Inspector, to improve the<br />
efficiency and productivity of its dynamic workforce.<br />
With Mincom’s enterprise solutions, TransGrid can achieve<br />
greater visibility, improved availability and increased return<br />
on nearly $6 billion worth of electricity assets, which provide<br />
electricity to more than three million households and businesses<br />
across New South Wales (NSW) and the Australian Capital<br />
Territory (ACT). TransGrid’s assets include 91 substations;<br />
12,600 kilometres of transmission lines; 36,000 transmissionline<br />
structures; and a workforce of more than 1,000 employees.<br />
“TransGrid is committed to supplying an efficient, safe and<br />
reliable supply of electricity – now and in the future,” said Mr.<br />
Tony Meehan, Executive General Manager of Finance and<br />
Information Systems. “Maximising the performance of our<br />
physical infrastructure and workforce is critical to meeting this<br />
objective,” said Mr. Meehan.<br />
“We selected Mincom Ellipse 8 as we believe it is currently<br />
the most robust and fully modern platform for enterprise asset<br />
management, designed specifically to meet the needs of assetintensive<br />
businesses like ours,” he said.<br />
“Mincom’s field-enablement applications are tightly integrated<br />
with Ellipse 8, which will assist TransGrid’s asset and work<br />
management processes in the field, where the work is being<br />
done.”<br />
Mincom Mobility is a suite of end-to-end field-enablement<br />
applications that improves the decision-making and productivity<br />
of field-force operations using mobile devices such as laptops,<br />
tablets, PDAs and more. Fully integrated with Mincom’s Ellipse<br />
solution for EAM, Mincom’s mobile workforce management<br />
solutions allow field personnel to perform the right job, with the<br />
right resources, wherever they are.<br />
“Utility companies around the world face significantly greater<br />
demand for energy due to rapid population growth, and must<br />
maximise the performance of their physical infrastructure and<br />
workforce to ensure continued reliability of service,” said Greg<br />
Clark, Mincom CEO.<br />
“We’re pleased that a recognised energy leader such as<br />
TransGrid has adopted Mincom Ellipse 8, integrated with our<br />
field-enablement applications, for this important function,” said<br />
Mr. Clark.<br />
www.mincom.com.<br />
Korsnäs Gävle chooses Intellinova with SPM HD for<br />
its fiber line<br />
The SPM HD measuring method has gained wide acclaim in<br />
the pulp and paper industry. Korsnäs, one of Sweden’s leading<br />
producers in consumer packaging, now invests in the Intellinova<br />
online system with SPM HD for condition monitoring on the fiber<br />
line of its production facility in Gävle.<br />
Korsnäs is a leading producer of fresh fiber-based packaging<br />
materials, mainly in consumer packaging. Production, with<br />
integrated pulp manufacturing, takes place at the company’s<br />
three facilities in Gävle, Frövi and Rockhammar. The production<br />
facility in Gävle, on the east coast of Sweden some 170 km north<br />
of Stockholm, has a total production capacity of 700,000 tons<br />
of paper and paper board annually on its three paper machines<br />
PM2, PM4 and PM5.<br />
Shortly after the launch of SPM HD in 2010, SPM was contracted<br />
to measure bearing condition on the preimpregnation vessel,<br />
using portable measuring equipment. At this point, before an<br />
upcoming maintenance stop, it was feared there was a bearing<br />
damage in the vessel. SPM HD measurements however showed<br />
there was no damage on the vessel bottom bearing. During<br />
a maintenance stop shortly after the measurements, it was<br />
confirmed that the disturbances detected earlier originated from<br />
other parts of the machine.<br />
Gunnar Rönning, maintenance engineer at Korsnäs, says the<br />
decision to invest in online condition monitoring was taken as<br />
a consequence of the successful measurements, and Korsnäs<br />
have high expectations for the SPM HD measuring method and<br />
its suitability for low speed machinery such as those in the fiber<br />
line.<br />
Installation on two continuous digesters, preimpregnation tower,<br />
high pressure feeder and wash press will take place during<br />
planned stops in May and June, 2011. This machinery normally<br />
runs at about 3-10 RPM.<br />
The fiber line in chemical pulp manufacturing covers the<br />
processes from wood to pulp: boiling, washing, filtering and<br />
bleaching.<br />
www.spminstrument.com/products/intellinova/<br />
Vol 24 No 3
Maintenance News<br />
57<br />
LogbooksOnline from OMCS International<br />
Web-based logbooks are the way of the future and OMCS<br />
International is leading the way, offering users a configurable<br />
system which can be used for any form of operation.<br />
Imagine the capability to design your own logbooks… for every<br />
part of your business… without the costly overhead of professional<br />
developers to keep it up to date as your requirements change!<br />
Using LogbooksOnline is like using a whiteboard…. Users can<br />
create their own fields, data types, calculations, trigger points<br />
and trigger functions!<br />
LogbooksOnline is a result of over a decade of research across<br />
all industry types. It is a simple and effective tool for improving<br />
methods of data collection and loss reconciliation and is designed<br />
to sustain any reliability initiative.<br />
LogbooksOnline is a module of one of the best reliability<br />
assurance software available, PMO2000®.<br />
For more information visit:<br />
www.omcsinternational.com/downloads/Production Log DemoV3_r1.pdf<br />
or www.reliabilityassurance.com<br />
or call OMCS International on 03 9315 0330<br />
IFS Applications selected by Brookfield Asset<br />
Management<br />
IFS has announced a contract with Brookfield Asset Management,<br />
a global asset manager focused on property, renewable power<br />
and infrastructure assets with over $100 billion of assets under<br />
management. Brookfield’s holdings include equity investments<br />
in commercial and residential real estate, pulp and paper mills,<br />
rail and port facilities, electric utilities and energy companies in<br />
virtually every country in the world.<br />
Brookfield will implement IFS Applications to streamline its<br />
business processes worldwide. With Brookfield Renewable<br />
Power having already implemented IFS Applications, their<br />
success was something the parent company and its various<br />
other divisions wanted to emulate. The company is licensing a<br />
broad suite of enterprise resource planning (ERP) and enterprise<br />
asset management (EAM) functionality including IFS Financials,<br />
Distribution, Maintenance, Project Management, Document<br />
Management and Human Resources.<br />
“Our affiliate, Brookfield Renewable Power, which had selected<br />
IFS for their ERP requirements, along with our own independent<br />
evaluation of available providers, led us in selecting IFS as our<br />
preferred strategic partner for an ERP platform for standardising<br />
our global operations,” Brookfield Corporate Operations Vice<br />
President of Global Strategic Sourcing Roman Kruczaj said.<br />
“Furthermore, their comprehensive financial management, strong<br />
projects functionality, and broad asset management features<br />
have the capabilities to meet our global requirements. IFS will<br />
provide us best-in-class applications to manage the diverse set<br />
of businesses we operate around the globe, including those that<br />
manage financial assets, ports, construction projects, power<br />
generation assets, and office properties.”<br />
The company offers a complete and integrated business<br />
solution that manages the entire asset lifecycle -design, procure,<br />
manufacture, build, construct and install, commission, maintain<br />
and service, spares and supply chain, repair, refurbish, and<br />
disposal. IFS Applications includes functionality for contract and<br />
project management, risk management, project budgeting and<br />
forecasting, finance and project accounting, resource planning,<br />
scheduling and optimization, asset and service management,<br />
spares management, mobile solutions for site work, call and<br />
case management including SLA, all fully integrated with human<br />
resources and document management.<br />
www.ifsworld.com<br />
PAC for compressor peace-of-mind<br />
The R-Series 90-160kW<br />
rotary screw air compressors,<br />
manufactured by Ingersoll Rand,<br />
offer the very best of time proven<br />
designs & technologies. Coupled<br />
with these, the compressors<br />
have many advanced features<br />
that ensure the highest levels<br />
of reliability, efficiency and<br />
productivity.<br />
The R-Series compressors utilise Progressive Adaptive Control<br />
(PAC) to protect the equipment and prevent unnecessary or<br />
emergency shutdowns of production lines caused by extreme<br />
situations or maintenance oversights. An integrated, intelligent<br />
system, PAC continually monitors key components and operating<br />
parameters and adjusts these to prevent unexpected downtime.<br />
For example, on a variable speed unit, should the filtration system<br />
start to clog or foul, the PAC will immediately display a real time<br />
warning and maintenance indicator. But unlike conventional<br />
compressor controls, should the situation deteriorate, the PAC<br />
will not shut down the compressor completely. Instead, the PAC<br />
will reduce the airflow so as to not overload the compressor<br />
cooling system. This protects the equipment, whilst giving the<br />
end-user time to rectify the problem, and maintain production<br />
without shutdown. An exciting innovation that saves time and<br />
money.<br />
The R-Series comes in four standard variants, designed to suit<br />
the load profile and duty required. The Fixed Speed version<br />
is available with single-stage or two-stage airend, giving up to<br />
15 per cent improved efficiency. For applications where there<br />
is significant variation in the air demand, the Variable Speed<br />
version is also available in single- and two-stage airend driven by<br />
the world-renowned Nirvana Hybrid Permanent Magnet motor.<br />
Typically, a Nirvana motor can save up to 35 per cent in power<br />
costs. Incorporating a two-stage airend can potentially add a<br />
further 15 per cent saving.<br />
CAPS Australia is confident that the R-Series gives world beating<br />
performance and no other compressor series in the market<br />
place is able to give a customer such exceptionally high levels of<br />
reliability and efficiency.<br />
www.capsaust.com.au/<br />
Photoelectric Sensors Cope With Washdown<br />
W Rockwell Automation<br />
has announced the release<br />
of the Allen-Bradley 42CS<br />
family of sensors, specifically<br />
engineered to address highpressure<br />
and harsh chemical<br />
cleaning conditions.<br />
These IP69K-rated sensors offer a wide range of sensing modes<br />
in a smooth or threaded 316L robust, stainless steel housing with<br />
hardened PMMA lenses. Smooth-barrel models, free of threads<br />
and seams, are designed to minimize the accumulation of<br />
undesired particles on the sensor and allow for an easy cleanup<br />
making it ideal for the food and beverage industry.<br />
Incorporated into the sensor is an innovative teach function that<br />
enables the user to easily optimise the sensitivity by placing a<br />
ferromagnetic metal object in the teach notch. In addition to the<br />
standard and precision teach modes, a lock-out feature prevents<br />
unauthorised users from changing the settings.<br />
www.rockwellautomation.com.au<br />
www.rockwellautomation.co.nz<br />
Vol 24 No 3
Maintenance News 58<br />
IFCS partners with MatrikonOPC. Secure OPC<br />
connectivity for Building Automation Customers<br />
MatrikonOPC has announced that IFCS is the newest member<br />
to join its Global Partner Network. IFCS will be integrating<br />
MatrikonOPC’s full range of OPC Servers with its DABO<br />
(Buildings Diagnostic Agent for Building Operation) – a powerful<br />
tool that analyzes and stores all data read by the centralized<br />
control system. The DABO also suggests corrective actions<br />
that can be implemented by the maintenance team even before<br />
problems manifest themselves. With MatrikonOPC’s secure and<br />
reliable OPC Servers, the DABO product can now be easily<br />
embedded into building automation networks around the world.<br />
MatrikonOPC solutions enable IFCS to configure all data<br />
transmission parameters by embedding the OPC Servers<br />
right into the IFCS solution. This capability allows for secure<br />
communication with all kinds of data sources – providing<br />
seamless integration across all building management systems<br />
and access to data wherever and whenever it is needed.<br />
“Secure access to real-time data is critical in building automation<br />
systems and data center applications - MatrikonOPC understands<br />
this need,” said Drew Brydon, vendor partner program manager-<br />
MatrikonOPC. “MatrikonOPC servers provide maximum security<br />
and connectivity to help users run their buildings and data<br />
centers more efficiently. Since IFCS’s primary focus is delivering<br />
effective, innovative asset management software that aims at<br />
enhancing buildings’ operations and efficiency, this partnership<br />
is a natural fit.”<br />
“MatrikonOPC’s solution is opening new opportunities for our<br />
products. Using OPC, we are now able to access and transfer<br />
any BAS data to our software regardless of the vendor. Thanks<br />
to MatrikonOPC our clients can now monitor and control buildings<br />
around the world,” said Xavier Bonifay, President, IFCS inc.<br />
Learn more about the MatrikonOPC Vendor Program here:<br />
www.matrikonopc.com/partners/oem.aspx<br />
Infor and KernMobile Increase Their Public Sector<br />
Capabilities with a Partnership<br />
Infor, a leading provider of business application software serving<br />
over 70,000 customers, and KernMobile, an Australian and New<br />
Zealand based company that provides a works management<br />
system for organisations with a mobile workforce, signed a<br />
reseller agreement across Australia and New Zealand.<br />
Under this partnership agreement, Infor will resell the KernMobile<br />
solution to extend the value of Infor Hansen Enterprise Asset<br />
Management that is used internationally within local government<br />
and utilities organisations.<br />
• The KernMobile solution integrates with both Infor Hansen 7<br />
& Infor Hansen 8 and is the mobile solution of choice for the<br />
Hansen product across Australia & New Zealand. It will provide<br />
added value to Infor clients by reducing their data management<br />
costs whilst at the same time, efficiently scheduling and recording<br />
field staff work orders.<br />
• The solutions is ideal for organisations dealing with off-site<br />
infrastructure or services as KernMobile provides an automated,<br />
paperless mobile data capture and works management system<br />
that links field staff with back office databases.<br />
• KernMobile has expertise in delivering data capture, asset and<br />
equipment maintenance, work crew scheduling and customer<br />
care, providing organisations with a big picture view of the<br />
company. It has been very successful at growing a client base<br />
in New Zealand and Australia. This partnership provides even<br />
greater local and global market reach.<br />
www.kernmobile.com www.infor.com<br />
Used CATs go mobile<br />
Leading UK business publisher The Moffat Group has developed<br />
an application for Apple’s iPhone and mobile-friendly website<br />
for Caterpillar, the world’s largest manufacturer of construction<br />
equipment.<br />
A new iPhone ‘app’ and<br />
mobile-friendly website<br />
from Caterpillar (CAT)<br />
has been launched.<br />
Updated in real time,<br />
the system provides<br />
pricing, specification,<br />
dealer location, machine comparison and contact information on<br />
approx 40,000 used CAT machines located across the globe. It<br />
also enables users to browse Cat Certified Used ®, which is only<br />
available from Cat dealers.<br />
www.resaleweekly.com/About-Us-Company-Profile<br />
International Society for CM (ISCM)<br />
In 2010 was launched the International Society for Condition<br />
Monitoring (ISCM) and many delegates at the CM2010 Condition<br />
Monitoring Conference showed an interest in joining. BINDT<br />
and the ISCM Interim Management Committee have been<br />
developing the terms and conditions of the ISCM, together with<br />
the membership benefits, and are now in a position to formalise<br />
membership and induction into the Society. The benefits of<br />
membership include:<br />
• facilitating a worldwide network for interchange of knowledge<br />
• encouraging and supporting national & international seminars<br />
and conferences<br />
• providing input in the development of training, qualification and<br />
certification programmes<br />
• contributing to the development of international standards<br />
• encouraging and supporting publishing initiatives<br />
• liaison with other national and international bodies<br />
• timely strategic planning<br />
• establishing sub-committees and working groups where<br />
appropriate<br />
The Chairman of the ISCM, Professor Len Gelman, wishes<br />
to invite you to join the International Society for Condition<br />
Monitoring.<br />
An application form and ISCM leaflet can be downloaded from:<br />
www.bindt.org/downloads/ISCM_Membership_Form.pdf<br />
www.bindt.org/downloads/ISCM_Leaflet_2011.pdf<br />
Singleton Council automates As-Built<br />
Open Spatial Australia has announced that Singleton Council<br />
has selected their As Constructed Design Certification Solution.<br />
By automating the As-Built / As Constructed / Work as Executed<br />
process, Council expects to be able to provide faster turnaround<br />
times to private developers submitting their Work as Executed<br />
drawings digitally.<br />
The Solution is will allow Council to accept electronic As-<br />
Built submissions from private developers to meet its digital<br />
requirements. Private developers will have access to published<br />
templates that describe the information needed by Council when<br />
at the end of the development phase. As-Built drawings, being<br />
a record of the design that was built, will contain the drawing<br />
and necessary attribute information to populate Council’s Asset<br />
Management system and its Geographical Information System<br />
(GIS) to help them better manage their infrastructure. Currently<br />
Vol 24 No 3
Maintenance News 59<br />
the process, validating the as-built to assure completeness and<br />
correctness and transferring the data from each submission into<br />
Asset Management and GIS, is largely manual. It is envisaged<br />
that by automating these submissions, Council will improve its e-<br />
services to its residents and developers working in the Singleton<br />
area, as well as allowing Council to do more with the same<br />
resources.<br />
Efficiencies gained by implementing this system will mean that<br />
the time that we previously spent re-capturing asset attributes<br />
and digitising as-built drawings can be used to further improve<br />
and enhance our asset management systems and practices.<br />
www.openspatial.com.au<br />
Infrared Windows for Switchboard Inspections<br />
To complement the range of thermal imaging equipment AIS<br />
introduces its innovative solution for switchboard inspections.<br />
Infrared Windows are widely used for thermal imaging inspections<br />
of switchboards and other industrial equipment without opening<br />
the covers.<br />
An infrared window assembly (composed of optics, O-ring, metal<br />
holder, and protecting cover) is installed as the viewport window<br />
for thermal imaging cameras. The critical part of the assembly,<br />
optics, is made of CaF2, which allows thermal imaging cameras<br />
to operate through it at different wavelength ranges. Our infrared<br />
windows are suitable for 3 wavelength ranges: 0.2-7um, 0.2-<br />
14um, and 3-16um. This window is also transparent for human<br />
eye for conducting visual inspections.<br />
An O-ring used in windows design meets the requirements of the<br />
dust protection standard IP67.<br />
www.applied-infrared.com.au<br />
LED Performance Benefits MRO Technicians<br />
G Designed for industrial maintenance technicians, the Pocket<br />
Floodlight combines the convenience and compact size of a<br />
penlight with the light output of a work light.<br />
Plant and equipment maintenance technicians often try to use<br />
a penlight-style flashlight instead of a work light when working<br />
in confined spaces since the flashlights are smaller, and are not<br />
tethered to an AC power outlet<br />
by an extension cord. However, a<br />
flashlight has a very narrow light<br />
beam with hot and dark spots<br />
which make it difficult to see<br />
what is being inspected. Also,<br />
the amount of light produced is<br />
far less than the amount of light<br />
produced by a work light. Maxxeon claims to have overcome all<br />
of these issues with their Pocket Floodlight which combines<br />
the size of a penlight with the performance of a work light.<br />
According to company spokesman John Schira, “This light is<br />
ideal for techs… they will be amazed at the massive amount of<br />
light that this tool produces. ”.<br />
The company claims that the light output of 120 lumens is up to<br />
20 times the amount of light produced by many penlights. The<br />
state-of-the-art LED has a special wide-angle light beam making<br />
it an ideal light for up close use. The special design provides<br />
a clear, uniform light pattern, without the “hot spots” and “dark<br />
spots” that are common to most flashlights.<br />
The Pocket Floodlight is also available with a UV LED for use<br />
in dye leak detection and red LED for night readings.<br />
www.maxxeon.com/led_pocket_floodlight_workstar_220.html<br />
<strong>AMMJ</strong> Sponsors and Supporters<br />
The <strong>AMMJ</strong> has been published since 1988 (originally as the Maintenance Journal). Our survival over<br />
those years has depended on the support given by our Advertisers. In these days of multi media options<br />
the <strong>AMMJ</strong> particularly wish to thank our major current Advertisers who have advertised with the <strong>AMMJ</strong><br />
over many issues:<br />
PLATINUM Sponsor and Supporter (Inserts and Multiple Page Advertising)<br />
SKF Reliability Systems rs.marketing@skf.com www.skf.com.au www.skf.com.au/training<br />
GOLD Sponsors and Supporters<br />
(Full Page Advertising)<br />
ARMS Reliability www.globalreliability.com<br />
FLIR info@FLIR.com.au www.FLIR.com.au<br />
Infratherm info@infratherm.com.au www.infratherm.com.au<br />
OMCS International steve@omcsinternational.com www.reliabilityassurance.com<br />
SIRF Rt www.sirfrt.com.au www.rcart.com.au<br />
The Asset Partnership mail@assetpartnership.com www.assetpartnership.com<br />
SILVER Sponsors and Supporters<br />
Apt Risk Management<br />
Assetivity<br />
www.aptgroup.com.au<br />
www.assetivity.com.au<br />
(Half Page Advertising)<br />
You can show your support for the <strong>AMMJ</strong> by taking a look at the advertising in this issue<br />
and by visiting the advertiser’s web sites.
Maintenance<br />
2011 Seminars<br />
Seminar 1<br />
(1 Day)<br />
The Why, What, How and Who<br />
Of Maintenance<br />
Maintenance Costs. What Maintenance Does Your<br />
Organisation Need. Deciding What Maintenance Can<br />
Be Applied To Your Assets. Planned Maintenance,<br />
Preventive, Predictive, and Proactive Maintenance.<br />
Maintenance People, Maintenance Skills & Structures.<br />
Seminar 2<br />
(1 Day)<br />
Maintenance Planning and<br />
Maintenance Management<br />
Maintenance Planning, Scheduling and Control,<br />
Maintenance Stores, Computerised Maintenance<br />
Management Systems, EAM’s and ERP’s, Maintenance<br />
History Collection, Using Maintenance Data. An Introduction<br />
To Maintenance Management and Asset Management.<br />
Who Should Attend:<br />
Tradespersons, Technicians,<br />
Planners, Schedulers,<br />
Maintenance Supervisors,<br />
Engineers, Managers and<br />
Operations Personnel.<br />
If your organisation is based<br />
in the Asia / Pacific Region we<br />
may be able to provide these<br />
Seminars in your organisation.<br />
Contact Len Bradshaw at<br />
mail@maintenancejournal.com<br />
Seminars 1 and 2 Presented By Len Bradshaw (Aust)<br />
Workshop<br />
(1 Day)<br />
Applying Best Practices to<br />
Maintenance Planning &<br />
Control<br />
Ricky Smith has worked in Maintenance for some of the Best companies in the World<br />
and also was a Maintenance Company Commander in Iraq and Kuwait. Lessons<br />
learned from this experience are identified and discussed in this Workshop.<br />
Developing Effective Work Procedures. The Roles of a Planner. Planning Proactive<br />
Work Process. Feedback on the Plan once it has been executed. Daily and Weekly<br />
Scheduling. What to do about a low wrench time. Maintenance Planning effect on<br />
Work Execution. Feedback to the planner and schedulers. Maintenance Metrics and<br />
much more.<br />
Venues<br />
Brisbane<br />
14 - 16 September 2011<br />
Melbourne<br />
19 - 21 September 2011<br />
Workshop Presented By Ricky Smith (USA)<br />
Organised By Engineering Information Transfer P/L and the Asset Management and Maintenance Journal
Seminar 1 Duration - 1 Day<br />
The Why, What, How and Who<br />
Of Maintenance<br />
Presented by Len Bradshaw<br />
Brisbane 14 September 2011 Melbourne 19 September 2011<br />
Seminar 2<br />
Duration - 1 Day<br />
Maintenance Planning and<br />
Maintenance Management<br />
Presented by Len Bradshaw<br />
Brisbane 15 September 2011 Melbourne 20 September 2011<br />
1. Consequences of Good or Bad Maintenance<br />
• The direct and indirect costs of Maintenance.<br />
• The real cost of failures and cost of downtime.<br />
• Do you identify and record real maintenance costs.<br />
• What do you cost and what are you worth.<br />
Displaying your value to your organisation.<br />
• Maintenance as a profit creator.<br />
• Short term and long term impact of insufficient<br />
resources in Maintenance<br />
• Effect of too little or too much planned maintenance.<br />
• Your Impact on Safety, Insurance and Legal Costs.<br />
2. Maintenance Activities<br />
• The different activities performed in maintenance.<br />
• Emergency, corrective, preventive, predictive,<br />
condition based, and Proactive maintenance.<br />
• Possible problems associated with fixed time<br />
replacement of components.<br />
• Understanding what are failures in maintenance.<br />
• The different failure types and how they affect what<br />
maintenance should be used.<br />
• What maintenance is needed. Basic rules in setting<br />
inspection and PM frequencies.<br />
3. Improving Maintenance Activities<br />
• Introduction to maintenance plan development.<br />
PM’s and repair proceedures.<br />
• Moving through Preventive / Predictive to Proactive<br />
Maintenance.<br />
4. Inspections & Condition Based Maintenance<br />
• What inspection and preventive/predictive techniques<br />
are now available in maintenance.<br />
• A look at the wide range of inspection and condition<br />
monitoring techniques<br />
• Visual inspections, oil analysis, vibration monitoring,<br />
thermography, acoustic emission, boroscopes, fibre<br />
optics, alignment techniques, residual current.<br />
5. The People and Structures In Maintenance<br />
• The different organisational structures used for<br />
maintenance activities.<br />
• Restructured maintenance, flexibility, multiskilling<br />
and team based structures.<br />
• What motivates people to work with the company<br />
rather than against it.<br />
• Maintenance Outsourcing/Contracting - for and<br />
against.<br />
• Introduction to what the best do: Leadership,<br />
recruitment, training, flexibility, motivation,<br />
teams, TPM, performance, rewards, core skills<br />
and outsourcing.<br />
1. Computerised Maintenance Management<br />
Systems<br />
• The different techniques involved with<br />
maintenance planning and use of a CMMS<br />
• The move towards Asset Management Systems<br />
and beyond the basic CMMS.<br />
• Links to other management systems, GIS, GPS,<br />
Internet, Intranet, Web based systems.<br />
• Who should be the planner. Responsibilities/<br />
duties of the planner.<br />
2. Maintenance Planning - The Details<br />
• Equipment coding, inventory and asset registers.<br />
Asset technical databases. Rotables.<br />
• Asset and task priority or criticallity.<br />
• Maintenance requests. Quick work request.<br />
• A PM becoming a Corrective task. The small job.<br />
• Backlog and frontlog files.Opportunity<br />
maintenance. Backlog file management.<br />
• Planning PM routines and corrective work.<br />
• Determining the weekly work. How much work?<br />
• Maintenance planning coordination meeting.<br />
• Work order issue, work in progress.<br />
• Feedback and history.<br />
• Performance measures for plant,<br />
maintenance, people and planning.<br />
3. Maintenance Stores<br />
• Store objectives and stock control.<br />
• Impact of maintenance type on stock held.<br />
• Who owns the stores? Who owns the parts?<br />
• Maintenance of parts in the store.<br />
• Vendor and user alliances. Consignment stock.<br />
• Monitoring service levels from your store.<br />
• Location of the stores.<br />
• Internet spares, parts optimisation,<br />
4. Maintenance Management<br />
• Using downtime data to minimise the impact of<br />
downtime.<br />
• Examples of how to collect, use, and understand<br />
maintenance data.<br />
• Maintenance - Using MTBF? Histograms, Pareto<br />
Analysis, Simulation.<br />
5. Asset Management<br />
• Introduction to Asset Management and<br />
Maintenance Excellence.<br />
• Introduction to life cycle costing of assets.<br />
• Introduction to Setting Strategies: Audits,<br />
Benchmarking, and KPI,s<br />
Who should attend these 1 day seminars?<br />
Tradespersons, Technicians, Planners, Schedulers, Engineers, Supervisors and Managers, plus Operations Personnel<br />
and others interested in maintenance of plant and assets.
Workshop Duration - 1 Day<br />
Applying Best Practices to<br />
Maintenance Planning & Control<br />
Presented by Ricky Smith<br />
Brisbane 16 September 2011 Melbourne 21 September 2011<br />
1. What does World Class Maintenance Planning look like?<br />
• Alcoa, Mt Holly – recognized worldwide as one of the best in the world.<br />
• Lessons learned from this experience are identified and discussed.<br />
2. Developing Effective Work Procedures<br />
• Why work procedures are necessary and becoming more critical<br />
• What the Work Procedure hierarchy is and why it is important<br />
• The difference between ranking jobs for execution and jobs for work procedure development<br />
• How to effectively map a work procedure<br />
• How to write clear and meaningful Warnings, Cautions and Notes for work procedures<br />
• How to identify and document constraints, impediments and resources for work procedures<br />
• Basic rules for work procedures<br />
• How to design and construct effective work procedures<br />
• Basic metrics for work procedure development and usage<br />
3. Proactive Work<br />
• Proactive Work Flow Model Attributes<br />
• The Roles of a Planner<br />
• The Roles of a Maintenance Supervisor<br />
• Planning Proactive Work Process<br />
• Kitting Parts<br />
• Managing the Backlog Overview<br />
• Feedback on the Plan once it has been executed<br />
4. Maintenance Scheduling<br />
• Daily and Weekly Scheduling<br />
• Wrench Time<br />
• Measuring Wrench Time<br />
• What to do about a low wrench time?<br />
• Scheduling one week of work load for your crew<br />
5. Maintenance Execution<br />
• Maintenance Planning effect on Work Execution<br />
• Maintenance Scheduling effect on Work Execution<br />
• Lack of / use of Effective Work Procedures<br />
effect on Work Execution<br />
• Feedback to the planner and schedulers<br />
• Work Order Close Out<br />
• Rework – how to eliminate it<br />
6. Maintenance Program Metrics<br />
• Metrics and Key Performance Indicators<br />
• Department Level Measures<br />
• Equipment or System Level Measures<br />
RICKY SMITH - Workshop<br />
Ricky Smith is renowned in the world of<br />
reliability and maintenance. He has more<br />
than 30 years of experience working in<br />
hundreds of plants world wide in reliability,<br />
maintenance management and training.<br />
Ricky has worked in maintenance at some<br />
of the World’s great companies including<br />
Alumax Mt Holly (now Alcoa Mt holly).<br />
Ricky spent one year in Kuwait and Iraq as<br />
a maintenance company commander for<br />
the US Army Reserve, where he provided<br />
maintenance to US and Coalition Forces.<br />
Ricky has developed an insight applicable<br />
to every maintenance facet.<br />
Ricky is also a well-respected author<br />
with his published books, “Lean<br />
Maintenance” and “Industrial Repair, Best<br />
Maintenance Repair Practices” with his<br />
latest book, “Rules of Thumb in Reliability<br />
Engineering”.<br />
Who should attend this 1 day workshop?<br />
Tradespersons, Technicians, Planners, Schedulers, Engineers, Supervisors and Managers, plus Operations Personnel<br />
and others interested in maintenance of plant and assets.
Len Bradshaw - Seminars 1 & 2<br />
Len Bradshaw is a specialist in maintenance<br />
management and maintenance planning/control. He<br />
is currently a Director of the Australasian Maintenance<br />
Excellence Awards. He is the Publisher/Editor of<br />
the <strong>AMMJ</strong> (Asset Management and Maintenance<br />
Journal) that reaches over 120 countries. He has<br />
a Masters Degree in Terotechnology (Maintenance<br />
Management).<br />
He has conducted maintenance seminars for all<br />
levels of maintenance staff from trades personnel<br />
to executive management. Len has conducted over<br />
320 courses for in excess of 9,000 maintenance<br />
personnel, both in Australia and overseas.<br />
Seminar and Worshop Fees<br />
AUD $750 per delegate (per day)<br />
The course fees are inclusive of GST and also include Seminar/Workshop material<br />
as well as lunch and refreshments. Course fee does not include accommodation,<br />
which if required is the delegates own responsibility.<br />
Confirmation A confirmation letter will be sent for each delegate.<br />
Times The courses start at 8:00am and end at 3:45pm, each day.<br />
Arrival/Signing-in is from 7:40am on the first day the delegate attends.<br />
2011 VENUES<br />
Brisbane: 14 - 16 Sept 2011<br />
Hotel Grand Chancellor<br />
23 Leichhardt St,<br />
Brisbane QLD<br />
Web: www.ghihotels.com<br />
Melbourne: 19 - 21 Sept 2011<br />
Rydges On Swanston Hotel<br />
701 Swanston St,<br />
Melbourne VIC<br />
Web: www.rydges.com<br />
How do I Register<br />
1. Mail the completed registration form together with your cheque made<br />
payable to: Engineering Information Transfer Pty Ltd,<br />
P.O. Box 703, Mornington, VIC 3931, Australia<br />
2. Scan form & email to: mail@maintenancejournal.com<br />
3. Email and Indicate courses/ dates/venue required/ personnel to<br />
attend and provide details of method of payment then email to:<br />
mail@maintenancejournal.com 4. Fax to: 03 59755735<br />
5. Or post/email a formal company Purchase Order/Purchase Order<br />
number and we will invoice your organisation on that Purchase Order.<br />
For Further Information<br />
Engineering Information Transfer P/L (ABN 67 330 738 613)<br />
Ph: Aus 03 5975 0083 Fax: 03 59755735<br />
Email: mail@maintenancejournal.com<br />
P.O. Box 703, Mornington, VIC 3931, Australia<br />
www.maintenancejournal.com<br />
Cancellations: Should you (after having registered) be unable to attend, a substitute delegate is always welcome. Alternatively, a full refund will be made for cancellations received<br />
in writing 14 days before the seminar starts . Cancellations 7 to 14 days prior to the seminar dates will be refunded 40% of the registration fee, in addition to receiving a set of seminar<br />
notes. There will be no refund for cancellations within 7 days of the seminar dates.<br />
This registration form may be photocopied.<br />
REGISTRATION FORM<br />
Course One: AUD $750<br />
The Why What When & Who of Maintenance<br />
Course Two: AUD $750<br />
Maintenance Planning & Maintenance Management<br />
Workshop: AUD $750<br />
Applying Best Practices to Maintenance Planning<br />
Course<br />
Please Tick Course<br />
Venue<br />
Please Tick Venue<br />
Brisbane<br />
Melbourne<br />
____________________________________________________________________________________________________________________________________________________________<br />
Name of delegate<br />
Name of approving officer<br />
Position<br />
Position<br />
Company/Address<br />
Phone<br />
Email<br />
____________________________________________________________________________________________________________________________________________________________<br />
Method of payment<br />
Fee payable $_________________<br />
Cheque - enclosed made payable to Engineering Information Transfer Pty Ltd<br />
Electronic funds transfer - Please email to obtain EFT details from:<br />
Charge to my credit card Mastercard Visa Card<br />
mail@maintenancejournal.com<br />
Other Cards are accepted but a 2% fee applies.<br />
Expiry Date_______________<br />
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PMS MAR RCF<br />
ML1<br />
FMC<br />
PMS MIC RCF<br />
ML1<br />
FMC<br />
PMS<br />
ML1<br />
Family & Co munity<br />
Day (ACT)<br />
BTM ESA ML1 RCF VA2 BTM PME PT OA1 BTM ESA<br />
RCF<br />
BTM BTM ML1<br />
VA1<br />
BTM BTM ML1 VA1<br />
VA3<br />
BTM<br />
VA3 BTM RCM<br />
VA3 BTM RCM<br />
VA3<br />
BTM BTM<br />
BTM BTM<br />
BTM RCF<br />
BTM<br />
OAM<br />
FMC<br />
OAM<br />
BTM<br />
FMC<br />
OAM<br />
BTM<br />
FMC<br />
OAM<br />
BTM<br />
OAM<br />
VA1<br />
RCM<br />
VA2<br />
MSR UT<br />
BTM<br />
VA2 PME PT<br />
FMC<br />
BTM<br />
VA2 MAR<br />
FMC<br />
VA2 FMC<br />
MSR UT ML1<br />
ESA<br />
SRM<br />
RCF<br />
SRM RCF<br />
SPM<br />
SPM<br />
OA1 BTM<br />
OA1 BTM RCF DB<br />
OA1<br />
VA3<br />
VA3 BTM<br />
RCF<br />
<br />
(WE201)<br />
NEW SOUTH WALES<br />
<br />
20- 2 <strong>July</strong><br />
<br />
10-12 August<br />
<br />
13-15 April<br />
<br />
8-10 June<br />
30 Nov-2 Dec<br />
<br />
23-25 February<br />
14-16 September<br />
<br />
23-25 March<br />
25-27 May<br />
19-21 October<br />
<br />
2-24 June<br />
NORTHERN TE RITORY<br />
<br />
23-25 February<br />
QU ENSLAND<br />
<br />
1-13 May<br />
12-14 October<br />
<br />
7-9 December<br />
<br />
1-3 June<br />
<br />
13-15 April<br />
<br />
2-24 June<br />
<br />
23-25 March<br />
19-21 October<br />
<br />
27-29 <strong>July</strong><br />
<br />
23-25 February<br />
<br />
2-4 March<br />
7-9 September<br />
<br />
19-21 April<br />
<br />
16-18 March<br />
23-25 November<br />
SOUTH AUSTRALIA<br />
<br />
25-27 May<br />
<br />
12-14 October<br />
<br />
28-30 April<br />
16-18 August<br />
7-9 December<br />
TASMANIA<br />
<br />
10-12 August<br />
VICTORIA<br />
<br />
1-13 May<br />
<br />
20- 2 April<br />
<br />
12-14 October<br />
<br />
7-9 September<br />
<br />
23-25 March<br />
21-23 June<br />
16-18 November<br />
WESTERN AUSTRALIA<br />
<br />
14-16 September<br />
<br />
21-23 April<br />
<br />
20- 2 <strong>July</strong><br />
<br />
9- 1 March<br />
16-18 November<br />
<br />
26-28 October<br />
PAPUA NEW GUINEA<br />
<br />
24-26 August<br />
FIJI<br />
<br />
7-9 <strong>July</strong><br />
<br />
13-15 <strong>July</strong><br />
NEW ZEALAND<br />
<br />
9- 1 February<br />
<br />
2-4 March<br />
<br />
23-25 March<br />
<br />
20- 2 April<br />
<br />
CAF<br />
1-13 May<br />
<br />
15-17 June<br />
<br />
20- 2 <strong>July</strong><br />
<br />
17-19 August<br />
<br />
DB<br />
7-9 September<br />
<br />
13-15 October<br />
<br />
2-4 November<br />
<br />
23-25 November<br />
<br />
14-16 December<br />
<br />
<br />
<br />
NEW SOUTH WALES<br />
<br />
9 February<br />
QU ENSLAND<br />
<br />
4 February<br />
VICTORIA<br />
<br />
1 February<br />
WESTERN AUSTRALIA<br />
<br />
ESA<br />
ESA<br />
2 February<br />
<br />
<br />
NEW SOUTH WALES<br />
<br />
28 October<br />
QU ENSLAND<br />
<br />
24 August<br />
SOUTH AUSTRALIA<br />
<br />
3 March<br />
VICTORIA<br />
<br />
29 April<br />
WESTERN AUSTRALIA<br />
<br />
21 <strong>July</strong><br />
<br />
<br />
NEW SOUTH WALES<br />
<br />
9 June<br />
1 December<br />
<br />
15 September<br />
QU ENSLAND<br />
<br />
23 November<br />
<br />
9 February<br />
<br />
CR<br />
12 February<br />
<br />
12 August<br />
SOUTH AUSTRALIA<br />
<br />
12 October<br />
VICTORIA<br />
<br />
25 February<br />
1 September<br />
WESTERN AUSTRALIA<br />
<br />
4 May<br />
<br />
26 October<br />
<br />
IR<br />
13 May<br />
5 November<br />
NEW ZEALAND<br />
<br />
24 March<br />
<br />
20 <strong>July</strong><br />
<br />
<br />
<br />
NEW SOUTH WALES<br />
<br />
16-17 March<br />
<br />
10- 1 August<br />
QU ENSLAND<br />
<br />
28-29 January<br />
<br />
MAR<br />
23-24 June<br />
SOUTH AUSTRALIA<br />
<br />
19-20 August<br />
WESTERN AUSTRALIA<br />
<br />
23-24 February<br />
<br />
<br />
MIC<br />
MIC<br />
NEW PLYMOUTH<br />
<br />
<br />
ON NORTH<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
LB1<br />
NEW SOUTH WALES<br />
<br />
12-16 April<br />
QU ENSLAND<br />
<br />
19-23 April<br />
WESTERN AUSTRALIA<br />
<br />
13-17 September<br />
<br />
<br />
QU ENSLAND<br />
<br />
25 May<br />
21 October<br />
WESTERN AUSTRALIA<br />
<br />
29 June<br />
21 September<br />
<br />
<br />
NEW SOUTH WALES<br />
<br />
24 August<br />
QU ENSLAND<br />
<br />
26 May<br />
SOUTH AUSTRALIA<br />
<br />
9 November<br />
VICTORIA<br />
<br />
8 <strong>July</strong><br />
WESTERN AUSTRALIA<br />
<br />
ML1<br />
2 September<br />
<br />
<br />
<br />
NEW SOUTH WALES<br />
<br />
28-29 January<br />
QU ENSLAND<br />
<br />
10- 1 August<br />
SOUTH AUSTRALIA<br />
<br />
14-15 <strong>July</strong><br />
VICTORIA<br />
<br />
3-4 February<br />
WESTERN AUSTRALIA<br />
<br />
MSR<br />
19-20 April<br />
<br />
<br />
<br />
NEW SOUTH WALES<br />
<br />
21-23 September<br />
QU ENSLAND<br />
<br />
9- 1 March<br />
<br />
13-15 <strong>July</strong><br />
<br />
1-3 June<br />
SOUTH AUSTRALIA<br />
<br />
4-6 May<br />
TASMANIA<br />
<br />
16-19 February<br />
VICTORIA<br />
<br />
17-19 August<br />
<br />
18-20 May<br />
WESTERN AUSTRALIA<br />
<br />
12-14 October<br />
NEW ZEALAND<br />
OA1<br />
<br />
23-25 March<br />
OA1<br />
OAM<br />
PME<br />
<br />
31 August-2 September<br />
<br />
<br />
NEW SOUTH WALES<br />
<br />
17-19 March<br />
QU ENSLAND<br />
<br />
30 August-1 September<br />
<br />
<br />
NEW SOUTH WALES<br />
<br />
20-23 April<br />
QU ENSLAND<br />
<br />
14-17 September<br />
SOUTH AUSTRALIA<br />
<br />
26-29 October<br />
VICTORIA<br />
<br />
27-30 <strong>July</strong><br />
WESTERN AUSTRALIA<br />
<br />
9-12 February<br />
NEW ZEALAND<br />
<br />
4-8 October<br />
<br />
<br />
<br />
<br />
QU ENSLAND<br />
<br />
2-26 March<br />
WESTERN AUSTRALIA<br />
<br />
23-27 August<br />
NEW ZEALAND<br />
<br />
23-25 February<br />
<br />
<br />
<br />
PMS<br />
PSF<br />
NEW SOUTH WALES<br />
<br />
7-8 September<br />
QU ENSLAND<br />
<br />
13-14 <strong>July</strong><br />
SOUTH AUSTRALIA<br />
<br />
15-16 June<br />
VICTORIA<br />
<br />
19-20 October<br />
WESTERN AUSTRALIA<br />
<br />
23-24 March<br />
<br />
<br />
NEW SOUTH WALES<br />
<br />
21-25 June<br />
QU ENSLAND<br />
<br />
26-30 <strong>July</strong><br />
SOUTH AUSTRALIA<br />
<br />
15-19 March<br />
<br />
13-17 September<br />
VICTORIA<br />
<br />
20-24 September<br />
WESTERN AUSTRALIA<br />
<br />
17-21 May<br />
<br />
RCM<br />
2-26 November<br />
<br />
<br />
<br />
NEW SOUTH WALES<br />
<br />
8 February<br />
QU ENSLAND<br />
<br />
5 February<br />
VICTORIA<br />
<br />
12 February<br />
WESTERN AUSTRALIA<br />
<br />
1 February<br />
<br />
<br />
QU ENSLAND<br />
<br />
17-19 November<br />
WESTERN AUSTRALIA<br />
<br />
5-7 May<br />
RCF<br />
<br />
<br />
<br />
NEW SOUTH WALES<br />
<br />
21- 2 September<br />
<br />
27-28 <strong>July</strong><br />
NORTHERN TE RITORY<br />
<br />
25-26 May<br />
QU ENSLAND<br />
<br />
16-17 February<br />
<br />
4-5 May<br />
<br />
28-29 October<br />
<br />
PT<br />
SPM<br />
2-3 February<br />
<br />
12-13 <strong>July</strong><br />
SOUTH AUSTRALIA<br />
<br />
23-24 November<br />
TASMANIA<br />
<br />
12-13 October<br />
VICTORIA<br />
<br />
16-17 March<br />
<br />
17-18 August<br />
WESTERN AUSTRALIA<br />
<br />
1-2 September<br />
<br />
15-16 June<br />
8-9 December<br />
NEW ZEALAND<br />
<br />
13-14 April<br />
<br />
9-10 November<br />
<br />
<br />
<br />
NEW SOUTH WALES<br />
<br />
9-10 November<br />
QU ENSLAND<br />
<br />
12-13 August<br />
SOUTH AUSTRALIA<br />
<br />
12-13 <strong>July</strong><br />
VICTORIA<br />
<br />
24-25 June<br />
WESTERN AUSTRALIA<br />
<br />
21- 2 April<br />
NEW ZEALAND<br />
<br />
18-19 May<br />
<br />
19-20 October<br />
<br />
<br />
<br />
NEW SOUTH WALES<br />
<br />
15-16 March<br />
QU ENSLAND<br />
<br />
2-3 September<br />
SOUTH AUSTRALIA<br />
<br />
13-14 May<br />
VICTORIA<br />
<br />
25-26 November<br />
WESTERN AUSTRALIA<br />
<br />
3-4 May<br />
SRM<br />
UT<br />
VA1<br />
<br />
<br />
<br />
SOUTH AUSTRALIA<br />
<br />
10-12 May<br />
VICTORIA<br />
<br />
2-24 November<br />
<br />
<br />
QU ENSLAND<br />
<br />
6-10 September<br />
WESTERN AUSTRALIA<br />
<br />
30 August-3 September<br />
<br />
<br />
NEW SOUTH WALES<br />
<br />
23-25 February<br />
QU ENSLAND<br />
<br />
2-24 June<br />
QU ENSLAND<br />
<br />
VA2<br />
VA3<br />
13-15 <strong>July</strong><br />
SOUTH AUSTRALIA<br />
<br />
10-12 August<br />
VICTORIA<br />
<br />
5-7 October<br />
WESTERN AUSTRALIA<br />
<br />
9- 1 March<br />
NEW ZEALAND<br />
<br />
13-15 October<br />
<br />
<br />
VICTORIA<br />
<br />
8-12 November<br />
WESTERN AUSTRALIA<br />
<br />
FMC<br />
26-30 <strong>July</strong><br />
NEW ZEALAND<br />
<br />
18- 2 October<br />
<br />
<br />
VICTORIA<br />
<br />
29 Nov-3 Dec<br />
NEW ZEALAND<br />
<br />
15-20 November<br />
<br />
<br />
NEW ZEALAND<br />
<br />
9- 1 March<br />
<br />
18-20 May<br />
<br />
27-29 <strong>July</strong><br />
<br />
24-26 August<br />
<br />
21-23 September<br />
<br />
20- 2 October<br />
And you thought<br />
we just made bearings<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
SKF Reliability Systems<br />
2010<br />
<br />
<br />
Australia Day<br />
<br />
<br />
New Years Day <br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
Labour Day (WA) <br />
<br />
<br />
<br />
<br />
<br />
<br />
Easter Monday ANZAC Day<br />
<br />
<br />
<br />
G od Friday <br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
Foundation Day (WA) Qu ens Birthday <br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
BTM CAF ML1 ML1<br />
DB MIC<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
<br />
SRM PMS PMS SRM<br />
Melb Cup (VIC) <br />
PMS BTM PMS BTM<br />
<br />
PMS BTM PMS BTM<br />
<br />
PMS BTM PMS BTM<br />
<br />
PMS PMS<br />
<br />
BTM ESA RCF ESA<br />
RCF<br />
<br />
Christmas Day<br />
Boxing Day<br />
<br />
<br />
<br />
<br />
<br />
BTM BTM NORTHERN TE RITORY<br />
2-24 June<br />
<br />
16-18 February<br />
25-27 May<br />
3-5 August<br />
2010 SKF Training Handbook<br />
For further information on<br />
Public, On site or future courses:<br />
03 9269 0763 rs.marketing@skf.com<br />
www.skf.com.au/training<br />
SKF Reliability Systems<br />
SKF Reliability Systems<br />
<br />
Reliability and maintenance training from SKF<br />
The development and knowledge path for your sta f to<br />
promote a productive, safe and innovative work environment<br />
The Power of Knowledge Engineering