May 2004 Alignment Tip Horizontal Moves without Jackscrews Further to our recent tip concerning preservation of the

Magnetic Center on motors with sleeve bearings when making horizontal moves, here are a few other things to look out for: If you do not have horizontal jackscrews to move your motor (and you have little excuse not to have them!), it is likely that you will be hitting the motor with a hammer to move it. Of course, this should be done only with a soft deadblow hammer. Furthermore, this also means you will be inclined to leave one of the four feet snugged nearly tight to help control your move. If so, consider that pivoting on a back foot has a greater effect on the offset than the angularity, while pivoting on a front foot has a greater effect on the angularity than the offset. Therefore, consider which alignment condition (horizontal offset or angularity) is the worse of the two before making your choice about which foot to leave snug. Also, depending on which direction you must move the motor, a move where you pivot on one snug foot will tend to either open the axial gap at the coupling or close it. It is imperative that you visualize what this effect will be prior to making your decision, so that the magnetic center of the motor and the proper axial gap clearance of the coupling is not unduly disturbed while making your moves. Of course, if you have jackscrews (as you should), it is always best to loosen all four feet and make your moves as needed without pivoting on any foot. Tip provided by LUDECA, INC. Distributor of the Rotalign PRO and Optalign PLUS laser alignment systems http://www.ludeca.com/ Tel: 305-591-8935 More Alignment Resources Motor Testing Tip Electrical windings shorts due to surges and transients tend to occur towards the motor lead connections in the winding. Degradation due to winding contamination, core problems or other defects will most often occur well into the motor windings. Motor circuit analysis is one of the technologies used to detect and trend degradation of insulation effecting the first few turns in the winding and is one of the few modern technologies that can detect and trend winding shorts deep into the motor windings (including DC fields), as well as across air gaps into

wound rotor motors and synchronous fields that are missed with older high voltage technologies. (References: EPRI AEMPM Study, May 2003; 2003 IEEE Electrical Insulation Conference Papers Inspection/Test Impact on Maintenance of Generators, Clyde Maughan, PE; Which Road Will You Take, Dave Humphrey, Allison Transmission; Estimating Motor Life Using Motor Circuit Analysis Predictive Measurements, Howard W Penrose, Ph.D.; and, Risk in Surge Testing of Turn Insulation in Windings of Rotating Machines, Bal Gupta, AOK Technologies). Tip provided by ALL-TEST Pro, A Division of BJM Corp www.alltestpro.com Tel: 860.399.5937 More Motor Testing Resources Total Lubrication Management White Paper and Presentation DMSI has prepared a presentation and white paper to get you started on tracking ALL your lubricated assets and keeping them operating effectively. It's based on the integration of lubricant management and analysis. View the white paper and visit DMSI at MARTS-2004 in Chicago May 24th-27th. Total Lubrication Management White Paper and Presentation Request

Maintenance Management Tip Key Performance Indicators The use of Key Performance Indicators (KPI) can help you answer many questions related to the maintenance activities at your facilities. Data can be viewed graphically for individual client plants or an accumulation of maintenance and inventory performance information for all plants. By viewing warning indicators pertaining to costs and performance, you can know where immediate actions are required. Before initiating a KPI program, there are several points that need to be considered: Remember, the use of KPIs can work both for and against you. Well thought out, they furnish sound data for sound decisions; poorly defined or misunderstood, they can lead to conflicts and poor management decisions. You must define what, how, and why you want to measure a particular activity or set of data. You should also have the authority to make the necessary changes as dictated by the KPIs trends.

 You need to develop KPIs that measure performance or cost from more than one view. You should have checks and balances in you program. An example might be if one metric goes up, common sense says another must go down. The more involvement in the KPI definition process by those participating in or having influence on a given KPI the better. Buy-in and understanding will make finding improvement opportunities as well as changes much easier. Be realistic when establishing your goals and expectations. Use the KPIs to drive constant and sustainable improvements. Communicate your KPIs and successes frequently and distribute as you deem necessary throughout your organization. As you develop your suite of KPIs you will find that some of the data that you want to see is not available or is difficult to retrieve. This may require you to modify work practices, data inputs, and even some software configuration. Tip provided by AssetPoint www.AssetPoint.com Tel: 864.458.3333 More Maintenance Management Resources Vibration Data Collection Tip A good diagnosis begins with good and repeatable data! Remember that when you are measuring vibration data with an accelerometer, you are actually measuring both the vibration forces produced by the machine, and the effect of the machines structure on these forces. For the same reason a doctor places a stethoscope on your chest instead of on your big toe when he wants to listen to your heart, always mount your sensor on a rigid structure as close to the bearings as possible. In order to essentially remove the effects of the structure from trend data, always be sure to mount your sensor in the same location test after test; preferably on a permanently installed stud mount. This Tip has been provided by DLI Engineering. http://www.dliengineering.com/ More Vibration Analysis Resources

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Their new utility style filter cart has practical work space. storage and all the standard features of their other portable filter carts. Call 1-888-925-8882 Toll Free or... Download a complete catalog at Y2K Fluid Power Inc. Maintenance Inspection Tip I had a situation come up today that had surprising results and I wanted to share with all. A customers site has 3 batch digesters that require internal inspections twice a year of a glass lining. The manufacturer does the inspections and the estimated cost of each trip out would average about $3000. These digesters are approximately 2 years old and no inspections have taken place as of yet however, there have been a few failures due to damage. The initial thought by the customer was to do all the digesters at once, semi-annually because then it would only cost $6000/year to perform. I stopped them, approached the dry erase board, and questioned their theory. In order to inspect all the digesters at once, this particular business unit has to completely shut down. The missed opportunity (measured as profit in this case) was $1000 dollars/hour to do this. The throughput and hours expended are directly proportional to each digester being in service. In other words, if one digester is down, capacity is reduced by 1/3 and the shut down/start up time are reduced by 1/3 as well. The chart below gives the business case of why 6 visits by the manufacturer are actually cheaper in the long run. Business Case for Digester Shutdown Schedule *Lockout, Flush, De-pressurize - 12 hours-Full Shutdown vs. 4 hours-Single Inspection *Cleanup - 12 hours-Full Shutdown vs. 4 hours -Single Inspection

*Inspection Time -12 hours-Full Shutdown vs. 4 hours-Single Inspection

*Start Up - 4 hours-Full Shutdown vs. 1 hour Single Inspection Total: 40 Hours-Full Shutdown vs. 13 hours-Single Inspection X Missed Opportunity $1,000-Full Shutdown vs. $333-Single Inspection Total: $40,000-Full Shutdown vs. $4,330-Single Inspection x Number of shutdowns 2-Full Shutdown vs. 6-Single Inspection Total: $80,000-Full Shutdown vs. $25,980-Single Inspection Cost of Inspection:$3,000-Full Shutdown vs. $3,000-Single Inspection Number is Instances: 2-Full Shutdown vs. 6-Single Inspection Total: $6,000-Full Shutdown vs. $18,000-Single Inspection Total Cost $86,000-Full Shutdown vs. $43,980-Single Inspection We gave the inspection cost the benefit of the doubt by assuming it would be

exactly the same per visit. You can see though that the site will actually save $42,000 per year by inspecting one digester at a time. This was not the original assumption since they would be tripling the cost to the manufacturer. Guess which schedule they are going to use? Tip provided by Tim White, CMRP Project Manager Management Resources Group, Inc. (MRG) Southbury, CT www.mrginc.net Thanks Tim - your Maintenance-Tips hat is on the way! More Maintenance Resources Find the RCM method that fits you best Reliability Centered Maintenance (RCM) is the premier approach for determining maintenance requirements. It can be applied to any system in any industry. There are many derivations and variations on the original classic approach to RCM, and all have value. But which one is best for you? Learn about RCM and its major variations and derivations at the Maintenance and Reliability Summit (MARTS) scheduled for May 24-27, 2004 in the Donald E. Stephens Convention Center in Rosemont (Chicago), IL. A virtual smorgasbord of RCM information Representatives of the major RCM methodologies will explain their approach in a unique all-day RCM & RCM-Linked Methods session in the Reliability Track at MARTS. Jack Nicholas, Jr., a neutral but experienced observer who is no longer engaged in RCM analysis, will chair the session and explain how RCM got started and grew. He will set the stage for six presentations by representatives of major RCM-linked methodologies: RCM Blitz, RCM Turbo, RCM Cost, Classical RCM, RCM 2, and PM Optimization. Register now for this outstanding session at www.MARTS-2004.com. MARTS is an educational and professional development opportunity for managers, technicians, supervisors, and engineers responsible for plant capacity and equipment availability. It is produced by Maintenance Technology magazine and Reliabilityweb.com, trusted sources for reliability and maintenance information. Find the RCM method that fits you best

Maintenance-Tips.com email is now delivered to over 32,000 subscribers! If you found these tips useful, please forward this email to someone else that may want their own copy. They can subscribe at the link below You are invited to submit a Maintenance-Tip of your own and get a free Maintenance-Tips.com cap if we publish it! Click on the link below and look for the "Submit a Tip" link on the home page. You may change your profile (choose Text, HTML or AOL format) or unsubscribe at anytime by using the links below. You can also contact us at the numbers below for these or any other requests. Advertisers who are interested in sponsoring an issue are invited to contact us at the numbers or email below. Terrence O'Hanlon, CMRP Team Publisher Maintenance-Tips.com PO Box 07070 Fort Myers FL 33919 USA Tel (239) 985-0317 tohanlon@reliabilityweb.com Disclaimer (to make the lawyers happy): These tips are supplied by third parties and are not warranted for any purpose. The reader is responsible for ensuring accuracy and compliance with all policies, regulations and laws. Copyright 2004 NetexpressUSA Inc., All rights reserved. Click here for a free Maintenance-Tips.com subscription and to submit your own tip!