Rules of Thumb for Maintenance and Reliability Engineers (eBook)

Front Cover 1
Rules of Thumb for Maintenance and Reliability Engineers 4
Copyright Page 5
Dedication Page 6
Contents 8
Introduction-The Recommended First Step to Rules of Thumb in Reliability Engineering 14
Part I: The Basics of Maintenance and Reliability 15
Chapter 1: Understanding Maintenance and Reliability 17
1.1. The Maintenance Function 17
1.2. Strategy to Achieve World-Class Production through Reliability 17
1.2.1. Maintenance Approaches 18
1.2.2. Maintenance Management Philosophy 18
1.2.3. The Function and Control System 19
1.2.4. What Is Maintenance? 19
1.2.5. Specification 20
1.2.6. The Maintenance Function 20
1.3. What Is Reliability? 22
1.3.1. Companies That Get It 22
1.3.2. Why Move Toward Proactive Work? 23
1.3.3. A New Way to View Failure 24
1.4. Maintenance/Reliability Assessment 24
1.5. Introduction to Change Management 28
1.6. Developing a Business Case for a Reliability Initiative 30
1.7. Calculating Return on Investment 33
1.7.1. Leadership of the ROI Team 33
1.7.2. Case Study 33
1.8. Planning and Scheduling 35
Chapter 2: The Functional Maintenance Organization and Its People 41
2.1. Functional Maintenance Organizational Structure 41
2.2. Maintenance Supervisor 43
2.2.1. Responsibilities 43
2.2.2. Environmental, Health, and Safety Aspects 44
2.3. Maintenance Planner/Scheduler 44
2.3.1. Responsibilities 44
2.4. Maintenance and Engineering Manager 45
2.4.1. Responsibilities 45
2.4.2. Environmental, Health, and Safety Aspects 46
2.5. Area Manager of Warehouse and Inventory Control 46
2.5.1. Responsibilities 46
2.6. Reliability Engineer 47
2.6.1. Responsibilities 48
2.6.2. Job Skills 48
2.6.3. Reliability Engineering Dashboard—Key Performance Indicators 49
Chapter 3: Preventive Maintenance Program 51
3.1. Reliability-Based Preventive Maintenance 51
3.1.1. Information Collection 52
3.1.2. System Analysis 52
3.1.3. Identification of Systems 52
3.1.4. Identification of System Functions 52
3.1.5. Selection of Systems 52
3.1.6. System Functional Failure and Criticality Rating 54
3.2. Identification of Functionally Significant Items 54
3.3. Maintenance Task Selection (Decision Logic Tree Analysis) 54
3.3.1. Levels of Analysis 55
3.3.2. Paralleling and Default Logic 57
3.4. Maintenance Tasks 57
3.5. Task Frequencies/Intervals 58
Chapter 4: Predicitive Maintenance Program 61
4.1. Setting Up a Preventive/Predictive Maintenance Program 63
4.2. Visual Inspection 64
4.3. Vibration Analysis 64
4.4. Thermography 67
4.5. Tribology 68
4.6. Ultrasonics 70
Chapter 5: Reliability Processes 71
5.1. Reliability Software—Managing the Health of Assets 71
5.1.1. Building an Effective Asset Reliability Program 72
5.1.2. Using Reliability Software to Put the Program into Action 72
5.1.3. Using Handheld Devices to Collect and Upload Condition Inspection Data 73
5.1.4. Plotting Asset Health Trends 75
5.1.5. Capturing the Experts’ Knowledge about Asset Condition 75
5.1.6. Integration to Enterprise Asset Management and Computerized Maintenance Management Systems 76
5.1.7. The Bottom Line 77
5.2. Seven Questions Addressed by Reliability Centered Maintenance 77
5.3. Failure Mode and Effects Analysis 80
5.4. Equipment Criticality Analysis 82
5.4.1. Preparing for an Equipment Criticality Analysis 85
5.4.2. Conducting the Review 86
5.4.3. Analyzing the Assessment Results 89
5.4.4. Using the Output of the Equipment Criticality Assessment 91
5.4.5. Conclusions 92
5.5. Root Cause Analysis 93
5.5.1. Plan 93
5.5.2. Do 95
5.5.3. Check 97
5.5.4. Act 100
Chapter 6: Key Performance Indicators 103
6.1. Defining and Understanding KPIs 103
6.1.1. The Problem 104
6.1.2. John Day 105
6.1.3. The Solution 107
6.2. KPI Dashboards 107
6.2.1. Plant Manager Dashboard 107
6.2.2. Plant Management Team Dashboard 107
6.2.3. Production Manager (Supervisor) Dashboard 108
6.2.4. Production Operator Dashboard 108
6.2.5. Maintenance Manager (Supervisor) Dashboard 108
6.2.6. Maintenance Staff Dashboard 109
6.2.7. Reliability Engineer Dashboard 109
6.2.8. Engineering Manager Dashboard 109
6.2.9. Purchasing Manager Dashboard 109
6.2.10. Maintenance Stores Manager 109
6.2.11. Conclusion 109
6.3. Measuring and Managing the Maintenance Function 109
6.3.1. Physical Asset Management 110
6.3.2. The Asset Reliability Process 111
6.3.3. Performance Metrics for the Maintenance Function 113
6.3.4. Reliability Process Key Performance Indicators-Leading Measures 113
6.3.5. Work Identification 113
6.3.6. Work Planning 114
6.3.7. Work Scheduling 114
6.3.8. Work Execution 115
6.3.9. Follow-Up 115
6.3.10. Performance Analysis 115
6.3.11. Key Performance Indicators of Maintenance Effectiveness (Result Measures) 116
6.3.12. The Importance of the Work Order 117
6.3.13. Reporting and Use of Key Performance Indicators 117
6.3.14. Conclusion 118
Chapter 7: Total Productive Maintenance 121
7.1. Introduction to Total Productive Maintenance 121
7.1.1. The TPM Organization 121
7.1.2. TPM Objectives 122
7.1.3. Autonomous Maintenance 122
7.1.4. Equipment Management 122
7.1.5. TPM Integration 122
7.1.6. TPM Is an Investment 122
7.1.7. Calculating Major Losses Is Key to TPM's Success 123
7.2. Lean Reliability 125
7.2.1. The Evolution from Lean Manufacturing to Lean Maintenance to Lean Reliability 125
7.2.2. Managing Asset Performance to Meet Customer Needs 126
7.2.3. The Basic Principles of Lean Reliability 128
7.2.4. How Lean Reliability Aligns with TPM, Kaizen, Five S, and Six Sigma 131
7.2.5. Key Elements to Implement and Sustain Lean Realiability 133
7.2.6. Summary 134
Part II: Equipment and Processes 135
Chapter 8: Chain Drives 137
8.1. Chain Selection 138
8.1.1. Plain or Detachable-Link Chain 138
8.1.2. Roller Chain 138
8.1.3. Sprockets 138
8.2. Chain Installation 138
8.3. Power Train Formulas 139
8.3.1. Shaft Speed 139
8.4. Chain Length 140
8.5. Multiple Sprockets 140
8.6. Chain Speed 141
8.7. Preventive Maintenance Procedures 141
Chapter 9: Hydraulics 143
9.1. Hydraulic Knowledge 143
9.2. Hydraulic Troubleshooter 143
9.3. General Maintenance Person 143
9.4. Best Maintenance Hydraulic Repair Practices 144
9.5. Root Cause Failure Analysis 144
9.6. Preventive Maintenance 144
9.7. Measuring Success 146
9.8. Recommended Maintenance Modifications 147
Chapter 10: Maintenance Welding 149
10.1. Shielded Metal Arc Welding (SMAW), “Stick Welding" 150
10.2. Flux-Cored Arc Welding (FCAW) 151
10.2.1. FCAW with Gas 151
10.2.2. FCAW Self-Shielded 151
10.3. Gas-Shielded Metal Arc Welding (GMAW) 155
10.3.1. GMAW for Maintenance Welding 155
10.3.2. Gas Selection for GMAW 155
10.4. Gas Tungsten Arc Welding (GTAW) 158
10.4.1. Applicability of GTAW 159
10.4.2. Advantages and Disadvantages of GTAW 159
10.4.3. Principles of Operating GTAW 159
10.4.4. Polarity and GTAW 161
10.4.5. GTAW Shielding Gases and Flow Rates 161
10.4.6. Electrode Material for GTAW 162
10.4.7. GTAW Electrode Size and Tip Shape 162
10.4.8. GTAW Electrode Holders and Gas Nozzles 163
10.4.9. Characteristics of GTAW Power Supplies 163
10.4.10. GTAW Torches 164
10.4.11. Manual GTAW Techniques 165
10.4.12. Establishing Welding Parameters for GTAW 165
10.4.13. Gas Tungsten Arc Starting Methods 165
10.5. Oxyacetylene Cutting 165
10.6. Air-Carbon Arc Cutting and Gouging 166
10.6.1. Applications 167
10.6.2. Power Sources 168
10.7. Plasma Arc Cutting 169
10.8. Welding Procedures 171
10.9. Qualification of Welders 171
10.10. Plasma Arc Welding 171
10.11. Base Metals 171
10.11.1. The Carbon Steels 171
10.11.2. The Alloy Steels 172
10.11.3. The Nonferrous Metals 174
10.12. Control of Distortion 174
10.13. Special Applications 175
10.13.1. Sheet Metal Welding 175
10.13.2. Hard Surfacing 175
10.13.3. Resisting Abrasive Wear 175
10.13.4. Resisting Impact Wear 175
10.13.5. Types of Surfacing Electrodes 177
10.13.6. Choosing Hard-Facing Material 177
10.13.7. Check Welding Procedure 179
10.13.8. Check Before the Part Is Completely Worn 179
10.13.9. Hard Surfacing with SAW 179
10.14. Selection and Maintenance of Equipment 181
10.14.1. Machines 181
10.14.2. Accessory Equipment 183
10.15. Installation of Equipment 183
10.16. Equipment Operation and Maintenance 184
10.16.1. Keep the Machine Clean and Cool 184
10.16.2. Do Not Abuse the Machine 184
10.16.3. Do Not Work the Machine Over Its Rated Capacity 184
10.16.4. Do Not Handle Roughly 184
10.16.5. Maintain the Machine Regularly 184
10.17. Safety 186
Chapter 11: Bearings 189
11.1. Types of Movement 189
11.1.1. About a Point (Rotational) 189
11.1.2. About a Line (Rotational) 189
11.1.3. Along a Line (Translational) 189
11.1.4. In a Plane (Rotational/Translational) 192
11.2. Commonly Used Bearing Types 192
11.2.1. Plain Bearings 192
11.2.2. Rolling Element or Antifriction 196
11.2.3. Roller 199
11.3. Bearing Materials 201
11.3.1. Plain 202
11.3.2. Rolling Element 202
11.4. Lubrication 202
11.4.1. Plain Bearings 202
11.4.2. Rolling Element Bearings 203
11.5. Installation and General Handling Precautions 204
11.5.1. Plain Bearing Installation 204
11.5.2. Roller Bearing Installation 204
11.5.3. General Roller-Element Bearing Handling Precautions 206
11.6. Bearing Failures, Deficiencies, and Their Causes 207
11.6.1. Improper Bearing Selection and/or Installations 207
Chapter 12: Compressors 213
12.1. Centrifugal 213
12.1.1. Configuration 213
12.2. Performance 215
12.2.1. First Law of Thermodynamics 215
12.2.2. Second Law of Thermodynamics 216
12.2.3. Pressure/Volume/Temperature (PVT) Relationship 216
12.2.4. Pressure/Compression 216
12.2.5. Other Performance Indicators 216
12.3. Positive Displacement 217
12.3.1. Rotary 217
12.4. Reciprocating 220
12.4.1. Configuration 221
12.4.2. Performance 224
12.4.3. Installation 224
12.4.4. Operating Methods 226
12.5. Troubleshooting 226
12.5.1. Centrifugal 226
12.5.2. Rotary-Type, Positive Displacement 226
12.5.3. Reciprocating, Positive Displacement 230
Chapter 13: Gears and Gearboxes 239
13.1. Spur Gears 239
13.2. Pitch Diameter and Center Distance 240
13.3. Circular Pitch 241
13.4. Diametrical Pitch and Measurement 241
13.4.1. Method 1 242
13.4.2. Method 2 242
13.5. Pitch Calculations 242
13.6. Tooth Proportions 243
13.7. Backlash 244
13.8. Other Gear Types 244
13.8.1. Bevel and Miter 244
13.8.2. Helical 245
13.8.3. Worm 246
13.8.4. Herringbone 247
13.8.5. Gear Dynamics and Failure Modes 247
13.8.6. Common Characteristics 249
13.9. Troubleshooting 250
13.9.1. Normal Wear 251
13.9.2. Abnormal Wear 251
Chapter 14: Packing and seals 253
14.1. Fundamentals 253
14.1.1. Shaft Seal Requirements 253
14.1.2. Sealing Devices 253
14.2. Mechanical Seal Designs 256
14.2.1. Single-Coil Spring Seal 256
14.2.2. Positive Drive 256
14.3. Installation Procedures 256
14.3.1. Packed Stuffing Box 257
14.3.2. Mechanical Seals 259
14.4. Troubleshooting 262
14.4.1. Mechanical Seals 262
14.4.2. Packed Boxes 263
Chapter 15: Electric Motors 265
15.1. Bearing Frequencies 265
15.2. Imbalance 265
15.3. Line Frequency 265
15.4. Loose Rotor Bars 265
15.5. Running Speed 266
15.6. Slip Frequency 266
15.7. V-Belt Intermediate Drives 266
15.8. Electric Motor Analysis 266
Part III: Additional Readings on Maintenance and Reliability 267
Chapter 16: Reliability Articles 269
16.1. Top Five Reasons Why Companies Don’t Measure Reliability: It Seems Like Everyone Has an Excuse as to Why They Don't Measure Reliability 269
16.1.1. Reason 1 269
16.1.2. Reason 2 269
16.1.3. Reason 3 269
16.1.4. Reason 4 269
16.1.5. Reason 5 270
16.2. Creating a Culture Change in Your Maintenance Department: Is Your Maintenance Crew in a Reactive Mindset? Check Out a List of Qualifiers to Find Out and Then Learn How to Change It 270
16.3. Exterminate Lube Problems: Grease and Oil Expertise Can Be a Serious Competitive Edge 271
16.3.1. Big, Bad, and Ugly 271
16.3.2. Make Lube Expertise a Specialty 272
16.3.3. Get the Job Done 274
16.4. What It Takes to Make the Climb from Reactive to RCM 274
16.4.1. Waving the Flag 275
16.4.2. Does Management Understand? 283
16.4.3. Who Owns Reliability? 284
16.4.4. Informal versus Formal Programs 284
16.4.5. To Measure Is to Manage 284
16.4.6. Depth of Understanding 285
16.4.7. Indicated Actions 286
16.4.8. Lessons Are Simple 287
16.5. Put a Plant-wide Focus on Functional Failures 288
16.6. Reliability Is Worth a Second Look: Statistical Analysis and Time-Based Preventive Maintenance Don't Really Address the Ability to Perform-It's Time to Get Familiar with the Definition of Reliability 289
16.7. When Preventive Maintenance Doesn’t Work 290
16.8. The Top Four Reasons Why Predictive Maintenance Fails and "What to Do about It" 291
16.8.1. PF Curve 292
16.8.2. Reason 1: The Collection of PdM Data Is Not Viewed as Part of the Total Maintenance Process 292
16.8.3. Reason 2: The Collected PdM Data Arrives Too Late to Prevent Equipment Failures 293
16.8.4. Reason 3: Many Companies Fail to Take Advantage of Data from PLCs and DCSs 293
16.8.5. Reason 4: Most PdM Data Is Dispersed in Too Many Non-Integrated Databases 294
16.8.6. Some Simple Guidelines Will Help to Get You Moving in the Right Direction 295
16.8.7. Summary 296
Chapter 17: MTBF User Guide: Measuring Mean Time between Failures 297
17.1. Understanding Definitions 297
17.2. The MTBF Process 297
17.3. Example 298
17.3.1. MTBF Percentage Change 298
17.3.2. Total Plant MTBF 298
17.4. Summary 298
Appendix A: Workflow for Planning 299
Appendix B: Checklists and Forms 301
Glossary 329
Index 333