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Reliability Engineering for MaintenancePosts about Capital Projects
Business Centred Maintenance
Registered Member Independent companies are exclusive organizations, associations, or sole ownerships that have less workers and additionally less yearly income than a normal estimated business or partnership. From; South African Trademark Search [ more ]
Registered Member Hi everyone, I am new to this forum but have some suggestions on business centered maintenance. My view is why not treat maintenance like a business? The goal of any business is to maximuize the outcome while minimizing the input. That is to improve the return on investment. In maintenance you do this by improving usable capacity, reducing costs and reducing the working capital investment. From this everything else follows. I could go on about how targeting PM programs is analogous to... [ more ]
Registered Member Did you have an industrial/pharmaceutical companies association back there in Malta? [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Steam turbine replacement by electrical motor, for Centrifugal compressor
Registered Member The design of the motor at 4000hp running at 6000rpm will be critical, the mechanical stresses on the windings especially winding overhangs of the rotor will require special material and construction, something to consider for long term management of the asset and its reliability. [ more ]
Registered Member Dear Johan, totally agree with you.. the challenge is huge.. I heard with modern VFD not is necessary to get Gear Box, because the VFD can reach 7200 rpm in the motor, that is enough for the compressor. but I dont know the power limits for this application. thanks. [ more ]
Registered Member Evening Ramon, some comments, depending on the voltage a VFD could be better option however voltage would dictate, high speed motors comes with its own challenges, keep an eye out for that, select gearbox carefully, high quality especially for that speed will be critical, wouldn't like to recommend publicly (can discuss with you if you are interested). Yes numerous ways to inspect and make foundation and base is suitable, would imagine if you go from steam turbine to electric motor there... [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Maintenance and Reliability Internet sites
Registered Member In case someone stumbles across this older post, feel free to check out www.roadtoreliability.com [ more ]
Registered Member Kindly include my website, I just uploaded this recently heres the link : www.rsareliability.com My Warm Regards, Rolly Angeles Teacher www.rsareliability.com [ more ]
Registered Member I'll agree there may be some energy dissipated in the damping of the pumped fluid if the motor is attached to a pump. We need to consider that along with the energy dissipated in the bearings. The energy dissipated in structures from vibration is still negligible. I still think it is not reasonable to estimate the energy put into the system or removed from the system based on the effort a human would perceive (break into a sweat). This was illustrated by my block example above. In short, you... [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
CMRP
Registered Member Dear All, I would appreciate it if you can send me any CMRP exam resources malameeng9@gmail.com [ more ]
Registered Member Dear All, Bet you are doing great. I have six years of military maintenance experience. I am provide real SMRP CMRP exam questions with exact answers. 100% Exam Passing Guarantee. I can give you very reasonably affordable price. Please contact ( catherinebirgnano@gmail.com ) [ more ]
Registered Member I have passed cmrp exam in my 2nd attempt. actually i tried to clear it with study first time around but i fell short and failed with only 60% marks. this time i have taken material from https://www.certkillers.net and it took me only 2 days to memorize those questions and then i appeared in exam and got 94% marks. i am thankful to certificationz advisor forum as they told me about this great certification website. you can view their demo at https://www.certkillers.net/demo/CMRP.pdf full... [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Seal selection for new pump
Registered Member Double mechanical seal based solely on the product MSDS. You should consult with a seal expert about this application, dangerous products require full understanding of materials of construction, flow paths, leakage. Here is a link for knowledge of seal plans http://www.sealfaqs.com/?page_id=184 Dave [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Fuel Injector-Calibrator
Registered Member hi bill, The information you are looking for is very difficult to find on the internet because the calibrator j-22410 is a machine that appeared between the sixties and seventies. in my inventory I have a kent-Moore injectors comparator J-7041 that I could put operational based on the little information I got in the detroit diesel maintenance manuals. I have the same calibrator as you but I lack the adapters for the injectors, if we could exchange information it would be great. Regards! [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
silica gel as a adsorben in instrument air dryer
Registered Member Ray, Silica Gel is important as an adsorbent to help control humidity/moisture. There are two types of gel available, plain, and indicator gel. Plain gel is clear and uncolored. Indicator gel is blue and turns pink as moisture is adsorbed to give an indication of excess moisture in systems where that is a critical parameter. I used to work in a plant that manufactured/packaged desiccants and we made a lot of packets and canisters containing silica gel. It is harmless for most uses and should... [ more ]
Registered Member Hi Ray, Sorry for late response. I have a long vacation. I have no clue on your system. But in general, you can check : Instrument air dryer system purging system Check your silica gel specification. Best Regards; Sati [ more ]
Registered Member Hi Sati, thanks for your response, what could you suspect if the root cause is from the air itself ? Is the choice of silica gel type important for specific system? [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Maintenance in CHP... suggestions please
Registered Member CHP conveyor systems should operate at maximum operating TPH with minimum running hrs. please focused on following issues 1.housekeeping of conveyor , gallery and equipment. 2Dust sprinkler system. 3.modern hydraulic tools ,jacks oil filtration machines and lifting machines. [ more ]
Registered Member I thought the OEM should have expected this kind of problems mentioned. So refering to OEM may help. However, can you just blow air to remove the dust from the conveyor parts? Sticky coal during rainy season - Is the conveyor covered with shed on top or even housed completely? Will washing down the conveyor help remove the sticky coal? [ more ]
Registered Member My one thought on this is about the conveyor. I feel confident you can run one conveyor independant of the other. If the is true pick your battles for the best and worst conveyor. You are looking for bang 4 buck and longivity. Then assess other fault areas or componants. Provide HMFIC the I can and I could scenario, let him say yes this will work If you are hmfic, hire the mfg to come in and survey the conveyors. That will tell you when and what and where. Get it fixed 1 conveyor at a time... [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Improving air-coal ratio
Registered Member you can increase the aph performance by introduction of new design seals this will increase the primary sir temperature and reduce use of total PA air. if coal is of low gcv and low VM then SADC adjustment can be done with metal temperature and spray quantity of boiler Superheaters and preheaters. [ more ]
Registered Member Our coal always had to meet certain standards before acceptance. That was the way it was written into the contracts. If you do not have that luxury then you have to run your boilers according to what coal you do have. The list I gave you before is a good starting point. Then you must center line your boiler to the type of coal you have. After you get to that point you can make small changes to your process. DOCUMENT what happened! If things were made better then that becomes your new center... [ more ]
Registered Member What is your issue? 1. Over the red line on the motor? 2. Feeder speed limitations 3. Overloaded coal mills? I miss the mark, but this is my 2 cents. Prior to increasing the air flow just because your fuel flow has increased. I find the measurement of coal/air ratios to be the biggest challenge. Understanding the coal rope and how coal flows thru the pipe, would come 1st. Think of silt in a fast river. The silt comes to a corner then lays up close to the bank before it snakes it way back to... [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Replacement of Normal API 610 Pump with Slurry handling pump due to change in process (25 WT % of Catalyst fines)
Registered Member As per plant process/ operation's response there is project to install filtration system on the slip stream to clean the catalyst from the system which is expected to be installed by end of 2020. With this project solid content of the circulating water is expected to go down to 0.01-0.02 wt% level. Now actually untill 2020 we don't want to continue damaging these pumps; I believe the selected slurry handling pump will be able to handle current conditions and the condition that will be... [ more ]
Registered Member Ok, I presume the high solids content is due to recirculation (you're not continually losing that quantity of catalyst otherwise you'd have a bigger problem than a worn pump). I would consider filtration downstream of your circulation pumps before changing your pump technology. [ more ]
Registered Member Originally these pumps were not designed to handle such high quantity/ % of Catalyst dust; therefore as per design there is a normal metallic mesh at the suction of these pumps. Which now get's damaged after every 2-3 weeks due to erosion. There is no filtration system installed at these pumps. [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
How to set Magnetic Center of the motor
Registered Member It's not unheard of for 2-pole motors to oscillate axially when uncoupled. Two factors drive this behavior to be more common in 2-pole motors than slower motors: 1 - 2-pole motors tend to have weaker centering force than slower motors due to fewer vent ducts or no vent ducts. 2 - 2-pole motors tend to have stronger air-related forces due to axial fan design. You can often see this by temporarily blocking off air entrance on double-end ventilated motors and looking for change in rotor... [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Packing vent flow - Make Up Gas Compressor
Registered Member Guys,One question.. not related to discussion but I am curious to know.I have seen some recip compressors with check valves and without check valves in packing vent lines so do we really need check valves in packing vent lines connected to flare? What can happne in case of no check valves in packing vent lines?I there any standard or spec to provide check valves in packing vent lines [ more ]
Registered Member I would use differential temperatures from packing vent to packing vent to determine if you indeed have a leak. H2 compression is difficult to diagnose as flows can be moderate before you get large temperature differentials. As was said, determine the calibration of the flow meter and lubrication rates to the packing. [ more ]
Registered Member Then, you should talk to the project consultant to get the rational for putting it there. I think this check should be done before doing the modification. [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Cooling Tower Retrofits
Registered Member Yeah, definitely we put Baldor Super E (gold) motors on most of our stuff with the drives. The electricity will justify it. Also, set it for a low speed idle, and you don't have to worry about the icing thing. Can't comment on the torque, we're in a relatively mild climate down here. [ more ]
Registered Member 1) maintenance costs on drives/motors 2) 10 Cell counter flow 3) Mtr Shaft horz (4-5-6) 1800 RPM (nom) 250HP FR 449T single speed 7-8) Fan shaft vertical Hudson 32.8 ft. dia/115 rpm 9) GB-Amarillo #1713 588 hp 15.5/1 ratio [ more ]
Registered Member Can you be more specific about the current installation for retrofit? Reason for retrofit Cooling tower type Motor shaft orientation Motor shaft speed Motor HP Speed-Type (single, 2-speed, variable) Fan shaft orientation Fan speed Thanks, Walt [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
New compressor needed - preferences?
Registered Member Spend the money up front on something that is properly sized and selected (recommendations by seller based on your stated requirements) with factory trained local service readily available. Install it right and operate and maintain it according to proper procedures and it should still be there when you retire. I have a devilbiss screw compressor in my shop at home and it has served me well but not often. At the time, they were making them in Jackson, TN and they have always seemed like a... [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Storage Cabinets
Registered Member Are these small spare parts for packaged equipment kept by maintenance/user themselves? Don't you store them in the centralized storeroom or warehouse with proper tagging and location number? [ more ]
Registered Member We are going to store small spare parts for packaging equipment. Right now they are on a shelf in bins and it takes forever to find anything. [ more ]
Registered Member I guess your storeroom or warehouse does not have these storage cabinets right now or are you storing spare parts on other locations? Anyway, what types of spare parts do you want to store in these storage cabinets? [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Shimming bearings
Registered Member Similar issue faced in a split casing pillow block of PA & FD Fan Shims were provided between outer race & Housing top half, PA - shim of 0.1 mm FD - shim of 0.6 mm the vibration velocity although reduced from 30 to 2 mm/s for PA but only for one day after that the vibrations on the shimmed bearing are 10mm/s horizontal... lets see till what extent it reaches [ more ]
Registered Member This would cause the housing to become out of round and I would only use this as a temporary fix until the housing can be replaced with a new one! If the parting line is reduced the point of bearing contact in the housing become 90 degrees away from the parting line. [ more ]
Registered Member Jingas Instead of changing the bearing housing you can scrap the parting planes faces split bearing housing . The best way to decide , how much to scrap the parting planes is to place shims of 0.5mm thickness (for example)on parting planes. Then place lead wire over outer race of bearing. Now put top half bearing housing on the bottom half.Tighten the bolts.Now Calculate x=0.5(i.e. shim thickness)-residual lead wire thickness. It should be around 0.010 to 0.020 mm(i.e. interference between... [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
GasTurbine V94.3A MW Lost
Registered Member Dear Maeda, check the IGV angle if not check the compressor blade tip clearance of the 1st stage and compare it with the good one. Probably tip clearance is the main reason. [ more ]
Registered Member Change analysis can be done by comparing operating parameters before and after HGPI and also comparing the losing capacity GT with the good GT to see any deviations or not. [ more ]
Registered Member Is firing and combustion good after HGPI like before HGPI? Are the operating parameters the same before and after HGPI? What are the inspection results? Any repairs done? http://www.scribd.com/doc/2909126/GAS-TURBINE-4 [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Any life-cycle costing examples?
Registered Member Is it always the case, Barry? Since you are retired, perhaps, you know any exceptions? [ more ]
Registered Member Quote "The article by Ron More on ISO55000 Asset Management seems to suggest that assets should be purchased based on lowest life-cycle cost instead of lowest initial purchase price, doesn't it?" What do you think candy? [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Hand Tools in the Field
Registered Member Hi Roger, As far as having the documentation on hand, I would probably use an tablet. I would keep the information on Evernote, if the site allows it. If you have cell reception you can call down whatever document you need if you have it stored in the cloud. Items you use often can be kept on the tablet for offline use. You could use the camera to document issues found and repairs made. Storing everything in one place makes it easier to make reports. If you have a safety checklist or pre job... [ more ]
Registered Member John, You mentioned having a motor winding department so I can only assume that you work for a motor manufacture or motor repair shop. I work for a motor repair shop, but work on-site at a refinery full time. All the tools I need are in my truck tool box along with a canvas bag. I go to the job, look it over and see what tools I need. Then I walk back to my truck and load up the canvas bag with the tools.At the end of each week I organize my truck box if needed. That's what works for me. [ more ]
Registered Member Hi John, I forgot to mention that this tool kit planning should also include technical drawings and procedures such as calibration, safety, or user notifications used to support the technician. There is no (reasonable) excuse for not having this level of preparedness for today’s technicians when you consider the technology available in data administration tools. Kudos to you for taking this on, this is a manager’s responsibility. They have responsibility for the organizations professional... [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Tool room
Registered Member Hi Pepzter, To answer your question of what you should put in the storeroom/toolroom: • No personal tools or PPE – other than such that is used to replenish the crafts workers stock • Specialized tools that the company owns that must be calibrated or monitored for safety such as scales, hoists, or any equipment requiring certification that the company is accountable for • Critical Spares – Repair parts with long lead times that you hope you never have to use but ABSOLUTELY must have on hand... [ more ]
Registered Member Yes there tool room is there, well before I joined the company. I shared with you by asking your available spaces, racks and walls and the tools that you have eight now.... In other words, use 5S. [ more ]
Registered Member Thanks Sir Josh I really appreciate it. I just want to make sure that our tool room will work because I am already the third person to take the lead for the project. Thank you very much.. May I ask you do you have a tool room set up at your industry? How does it look like? [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
CMRP
Registered Member Hi Ahmed, When I took my exam for Certified Maintenance Reliability Professional (CMRP) from the Society of Maintenance and Reliability Professionals and (SMRP) Certified Plant Maintenance Manager (CPMM) from the Association for Facilities Engineers (AFE) there was a study guide specifically given to me that was endorsed by both groups. Mine came from Clemson University and were titled “CPMM Review Pak” and were part of a course call Maintenance Excellence for Maintenance Managers. If you... [ more ]
Registered Member - ...do not underestimate the contribution Experience can and does have on successfully taking this examination. Dana P. -CMRP [ more ]
Registered Member Looking though my emails I found the following list as a MINIMUM reading list:  Reliability-Centered Maintenance 2nd Edition [Amazon ]: Focused on equipment reliability. Acquaintance with the entire contents of the book, including appendices, would be useful. Focus on chapters 2-11 and appendices 2 and 4.  Making Common Sense Common Practice [Amazon | Book Review] Focused on business management. Walks you through a hypothetical corporation called Beta Industries and its transformation to... [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Purchase the pump as API 610 edition 11th
Registered Member Centrifugal API 610 10th Edition OH6 and ISO 13709 Pumps are ideal for critical heavy-duty process applications. The impeller is directly mounted to the gearbox output shaft and there is no coupling between the gearbox and pump. That's why the gearbox is flexibly joined to its driver. The pumps may be oriented verticall or horizontally. [ more ]
Registered Member I would ask seal design to fulfill API682 and let the pump manufacturer to decide which plan is the most appropriate. After you have all quotations available make technical comparison between offers and evaluate pros&cons of each proposals etc... I would consider canned pump in your case since pumped media is carcinogenic. For canned pump API 685 is applicable. [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Roller coaster reliability
Registered Member Priceless! [ more ]
Registered Member They did have a PM program for the roller coaster wheels though. [ more ]
Registered Member I did an alignment on a roller coaster drive once. The motor mount was 1/8" too high to align the motor and gearbox and the chain and sprockets that convey the cars up the incline was badly misaligned so that the sprockets had visible wear on one side. I wanted to fix the installation and they wanted a certificate stating that there were no alignment issues. I wouldn't give them one and never heard from them again. I don't ride amusement rides anymore, but I would guess that the big parks... [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Cable train/car
Registered Member 4 pole induction motor as prime mover, so something just short of 1800 RPM input. I'd be guessing at the output shaft, those large overhung pulleys, but somewhere in the region of 50 RPM I suspect. I base that on some assumptions; say a pulley diameter of 10 feet and a maximum peripheral velocity of about 1500 ft/min. Why 1500 ft/min? Keep in mind these were originally built in the late 1800' so the pulleys were likely iron castings. The pulleys drive the cable (I have a piece given to me in... [ more ]
Registered Member It sounds reliable. What is the speed? [ more ]
Registered Member From the period of about 1982 to 1984 I was heavily involved in the replacement of the gearboxes used in the San Francisco Cable Car system. Actually the entire system was rebuilt/refurbished at that time, which was about the 100th anniversary. Most of the stationary equipment is housed in what is called the Cable Car Barn & Powerhouse at 1201 Mason Street, San Francisco. The facility is open to the public and well worth a visit. Among other notable things the facility is listed on the... [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Skirt Systems frame
Registered Member Which way is the frame bending? Is it bending down into the belt or out towards the belt? In my past,I have found that down is usually due to loads placed on steel work. This could either be from material weighing down the system or the support system causing a force to be applied to a frame. Out can be because of loads, but I have seen where temperature differences between the inside and outside of a frame will cause bending. I actually saw where solar loading on fiberglass skirts cause the... [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
pipelines in petrochemical ,oil industries protecttion against lightning
Registered Member Giri, If you are a newcomer to the industry,I am not clear as to why you picked this particular topic – there must be a host of others. Anyway, here is a link you may find useful. I am sure you can find many more on the web. http://pipelinesoz.wordpress.c...012/03/16/lightning/ The general principle is to - try to prevent exposure to strikes if possible, by having them lower than other structures, but this is not always possible - Having lightening conductors to draw the strikes away from... [ more ]
Registered Member Any lightning arrestors? [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
degree of turn of turbine heating bolts
Registered Member What is the MW of your turbine? What are the steam conditions in LP turbine? We tighten even inner casing bolts with hammer or pnumatic wrench. Vibmaster [ more ]
Registered Member Cold torquing is not sufficient LP Turbine has two cylinders and inner cylinder bolts required hot tightening [ more ]
Registered Member since it is low pressure casing, slogging is sufficient [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Boiler PM
Registered Member Jim, There is a legal obligation to maintain a record of your assets for accounting and reporting purposes. Also called an Asset Register, it is usually within the CMMS. This record needs unique (functional location) identification by Tag No. From a Reliability and maintenance cost management point of view as well, functional location numbers are necessary. I like Aubrey's method; from a safety management point of view, it is very helpful. [ more ]
Registered Member In any CMMS, every equipment should have tag numbers and assigned a number. There should be a tagging system available to be followed for eqpt without any tag nos. [ more ]
Registered Member Just my opinion, but I like tags on everything. This helps make sure you are working and inspecting the correct piece of equipment. Matching tags back in the MCC room helps ensure you have locked out the right piece of equipment. People don't do well with just a number. It is a lot easier to remember boiler feed pump #1 rather than 101-23-123. Computers and SAP love numbers. That is why most CMMS systems have both. Just my 50th of a dollar, [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Flex plate distorted
Registered Member You may have the sequence of events reversed. If the shaft jammed and then the motor tripped perhaps the sudden loss of rotation on the driven end caused an overload of the flex plate. [ more ]
Registered Member What type of coupling it is? If it is disc coupling, severe misalignment or wrong assembly procedure may be responsible. Pl post pictures of broken coupling. Vibmaster [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
breaking the sprocket tooth mine,s showel
Registered Member Javad, Send some snap shots/ photos of the broken sprocket for the forum members to view and comment. The failure could be due to many different type of reasons e.g. material issue, manufacturing defect, over loading, fatigue failure, increased backlash, etc.. Give some more information to us for giving comments. [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Ge10b-1
Registered Member plz any one have a document about ge10 gas turbine [ more ]
Registered Member If you go to www.ge.com and dig a little deeper You would find a page/link here > Technical Manuals for Gas and Steam Turbine Generator Units Where you can register and download GE Technical Manuals. I do not know if they have the specific one you seek...you will have to find that out that yourself! [ more ]
Registered Member I think the only way to get relevant manuals is to contact your GE CPM if you have a contract, or your local GE reperesentative. If you are the registered owner of the unit they should be able to supply you with the original GEK manuals for the unit. If it is fairly new (newer than 2003 or 4 I think) they have all the manuals electronically. [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
Tools List for Steam/Gas Turbine Major Overhaul
Registered Member Thank you Richard [ more ]
Registered Member try this: [ more ]
Registered Member To Richard Heiden, Thank you for the post. "Nizz" isn't the only neophyte on this forum. After seven good years with the railroad, and five as a "P.I.," the energy field, and more specifically, Turbine maintenance, is a new challenge for me. Your list is incredibly helpful to those who want to learn. Unfortunately, my Windows-based "hp" is balking at displaying the document in it's "word" format. Is there another place to access the entire list, as I can only view half of it currently..? [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
balancing a rotor after shaft Run out Correction
Registered Member Think about the task of balancing; it is the act of adding (or the removal) of small masses (weights) to a rotor in order to reduce the 1X vibration levels. You don't give any specifics but isn't this essentially what you did by "correcting shaft runout that is out of tolerance". You've removed a small mass when you corrected the runout in which case you almost certainly have upset the balance state to an unknown degree. You have to make the decision based on the specifics. Was the... [ more ]
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