Your Reliability Engineering Professional Development Site
A listing in reverse chronological order of these article series:
I found myself seated next to a corporate executive in a recent flight out of Atlanta, while I was attempting to read a book, he was yammering away on his cell phone about quarterly results and the need for a reduction in head count. Hearing this, my hopes of becoming engrossed in a good book was now over. Now I’m just upset at how some folks seem to make life changing decisions with such little regard or emotion. [Read more…]
A belt conveyor is a moving surface used to transport product from one end to the other. In its basic form it consists of a driving head pulley, a tail pulley, the moving belt, support rollers, cleaning devices, tensioning mechanisms and a structural frame. Though simple in concept its many components need to work together as a system to get the best performance and operating life. Critical to that is an understanding of how to care for a belt conveyor and tune it for successful operation. [Read more…]
I get mad at Stan Nowlan and Howard Heap from time to time. Twenty years ago their work titled Reliability Centered Maintenance became the focus of my life when I first discovered the impact that RCM could have on manufacturing reliability. Since that time, I have authored somewhere around fifty articles on the subject, been a featured speaker at nearly three conferences a year and several years ago I even completed a book on the subject, describing what I see as the most effective way to complete a RCM analysis as well as the impact it can have on equipment and process reliability (Reliability Centered Maintenance using RCM Blitz™). For those who have taken the time to become educated in what a good RCM analysis is all about, they know power of this tool and where it applies. I know from experience, Reliability Centered Maintenance can and will deliver incredible results. [Read more…]
Moving slurries about. Slurry is solid particles in a liquid. Concentration can vary from mostly liquid to mostly solid. Slurries are usually transported through pipe work using pumps, pressurised gas or steam. Different concentrations and different particulate produce different flow characteristics. Successful slurry transport requires knowledge of the particulate, its transport behaviour in the liquid at different concentrations and speeds, the nature and friction effects of the pipe work system and selection of the right motive method for the application. This article provides information for transporting slurries of up to 60% solids concentration. [Read more…]
Abstract
Effect of process changes on electric motors. This article explains the effect of changing process loads on AC induction electric motor performance. The motor’s behaviour is a response to the load imposed on it by the equipment connected to it. The equipment’s behaviour is itself a response to the duty and service it has to perform. Where the equipment duty and service is adjustable by the operator, or fluctuates as the process changes, the motor will react to those changes. When the changes are so excessive that they are beyond the motor’s ability to handle them the motor stops and the equipment or process stops with it. Keywords: squirrel-cage motor, overload. [Read more…]
Thirty-three years ago, I graduated as a Journeymen Pipefitter from a three-year skilled trades apprentice program and went to work as a Journeymen at Eastman Kodak. At that time in my life I had no idea where this training would take me. I was simply honored to work alongside those who in mentoring me, passed on a set of skills that would last a lifetime. [Read more…]
The 5 s method of operation – A Five S program focuses on having visual order, organization, cleanliness and standardization throughout the workplace and the operation. It is a structured method to put operators and maintainers in control of what they do. [Read more…]
Grease and oil are the key lubricants used throughout industry to reduce friction between metal parts. Lubricants can only reduce friction if their immediate environment sustains their lubricating properties. Once the operating conditions are known a suitable lubricant with the right properties can be used. When the lubricant is in place it is necessary to maintain the environment and the machine to the specified design standards and protect it from changes to the design conditions. There are six key factors to address for trouble- free life where grease or oil lubrication is used on machinery. [Read more…]
Discipline, look it up in the dictionary and you will find the following definition; the practice of training people to obey rules or a code of behavior, using punishment to correct disobedience.
People tend to get nervous when the word Discipline pops up at the top of a presentation. Truth is there are several definitions to this word. As an example, Discipline is also a branch of knowledge one studies in higher education. [Read more…]
The Big Bang – starting and stopping equipment under load. When a machine starts-up its parts move from zero speed to operating speed in a short time (the reverse when stopping). During this short period the biggest forces that the machine experiences act on its components. If during the start-up or slow-down the product or process loads are added to the machines own self-loads the forces acting on the machine’s parts are horribly magnified. If these impulse forces exceed the machine’s design allowance, or cause gradual fatigue, then the stressed parts will shatter without warning. [Read more…]
Imagine being able to easily share information across sites or even organizations. Or how about utilizing a risk management framework that is recognized and agreed upon by all in the organization. Benchmarking made easy? Standards enable this. [Read more…]
Rotating shafts under bending stress. It is common to transmit motion using rotating shafts. The shafts are mounted in bearings and turned by force through a drive arrangement. The shafts usually also carry a load. These loads cause bending and the shaft reacts by producing counter stresses within itself. Provided the reactive stresses are within the shaft’s strength range it will take the load. But if the stresses are greater than what the shaft can take it will bend. Even if the stresses are below the load limit but fluctuate, it is possible that the shaft will break from fatigue. The point of highest stress can be found by looking at the arrangement of the shaft supports and loads and calculating the forces and stresses.
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One of the best things about my job is from time to time I get to work with some fantastic young people who have a passion for the Maintenance and Reliability business and have made the decision to pursue a career in this business. I really enjoy being a mentor, guiding the ambitious and offering advice on where to find information, articles and real, workable solutions. [Read more…]
Imagine if every day you had to relearn a process or use a different CMMS. Chances are you would get virtually nothing accomplished, leaving your plant operating poorly. Now we all know that we having to relearn a process every day or using a new CMMS is not practical nor is it rooted in reality (not to be confused with the Rooted in Reliability podcast). But this type of thing happens more often than you may think. [Read more…]
Orifice plate meter flow measurement. An orifice meter is a circular piece of metal plate placed between flanges in a pipe. In it is a square-edged round hole machined 0.5 to 0.8 pipe diameter in size. Pressure tapping points are placed either side of the plate at specified distances. The orifice causes a flow restriction and produces a pressure drop from one side of the hole to the other. The amount of pressure difference is proportional to the flow of fluid through the hole. The flow is calculated from the pressure difference and flow areas using accurate mathematical formulas. [Read more…]