Ten Steps to Pump Reliability – Part 1

By Tom Dabbs and Dan Pereira

Pump reliability is an old topic, but it is just as relevant today as it was the first time we heard it a few decades ago. There are some very good reasons to focus on improving pump reliability:

  • The average annual maintenance and operations spending on centrifugal pumps is 50 percent greater than for any other type of rotating machine (FiveTwelve Group, August 2006).
  • Centrifugal pumps in many plants consume more than 50 percent of total plant motor energy (Hydraulic Institute).
  • Pumps consume more energy than any other class of industrial equipment (U.S. Department of Energy, 2005).
  • A Finnish Research Center study of centrifugal pump performance (“Expert Systems for Diagnosis and Performance of Centrifugal Pumps,” 1996) found that the average pumping efficiency was less than 40 percent for 1,690 pumps reviewed across 20 different plants, including all market segments. The study also revealed that 10 percent of the pumps were less than 10 percent efficient.

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Failure Teaches Success

By R. Keith Mobley, Principal SME, Life Cycle Engineering
As appeared in th
e July 2014 Edition of Reflections on Excellence

I absolutely hate to fail, but must admit that failure is an unescapable part of life. Thankfully most of my failures over the years have been relatively minor. Nonetheless, they have been a true source of irritation and frustration that in many ways outweigh the successes. Fortunately my early mentors taught me to use failure, no matter how serious or minor, as a learning tool and a platform to build upon. That lesson, combined with Mobley’s 10th Law, “Making the same mistake twice is unforgivable”, has played a major role in my successful journey over the past five decades. With each failure, my knowledge and expertise increased, enabling faster and surer growth. Continue reading

Maintenance Tip – Oil Sampling

By Terry Taylor, IDCON INC

The most important point about oil samples and oil analysis in general is you are looking for any “change” that is taking place.

In order to see a “change”, each sample must be taken in a consistent and repeatable manner. Oil Sampling can be accomplished in a many ways. However, there are only a few ways in which the sample can be correctly captured. Continue reading

Focusing RCM on Equipment Critical to Electrical Safety

by H. Landis Floyd, PE, CSP, CMRP, Fellow IEEE

Business and commerce are totally dependent on electrical equipment and systems for energy, control and communications. These systems can be complex and the task to analyze failure consequences can be equally complex. Unrecognized consequence of failure, especially if the failure impacts personnel safety, can have unacceptable moral and legal implications as well as significant financial costs. Recent trends in workplace electrical safety shed new light on reliability needs for certain equipment in electric power and control systems. One trend is the increasing attention given to mitigating arc flash hazards in electric power systems. Continue reading

Leadership in Maintenance Weekly/Daily Operations and Maintenance Meetings

by Torbjörn Idhammar

Daily and weekly meetings between operations and maintenance are crucial in taking the efficiency of your daily maintenance to a higher level. Many organizations deal well with production stops, but have issues with organizing routine work. Coordinating meetings where various departments prioritize work orders (WO) and maintenance is the foundation for a partnership between operations and maintenance. Such meetings create efficiency. Well-organized meetings with clear goals and agendas can completely change the culture for the better in an organization. Continue reading

The New Productivity Challenge

by Peter F. Drucker
Harvard Business Review

The single greatest challenge facing managers in the developed countries of the world is to raise the productivity of knowledge and service workers. This challenge, which will dominate the management agenda for the next several decades, will ultimately determine the competitive performance of companies. Even more important, it will determine the very fabric of society and the quality of life in every industrialized nation. Continue reading

What Do Your Preventive Maintenance Tasks Really Do For Your Asset Care Strategy?

By Jeff Jones
As appeared in the June Edition of RxToday

Proper asset care is critical to ensure that equipment is available to meet production schedules, support process flows and comply with environmental, health, safety, and regulatory requirements. Asset care is the execution of the most cost effective control strategy to address the predominant failure modes of that particular asset with its operating envelope. The intent of this strategy is to provide the required asset utilization at the lowest life cycle cost while also ensuring the asset makes it to the budgeted end of life. This care could be an operator care task, a predictive technology, a preventive maintenance task or job plan, and even doing nothing at all (run to failure). The asset care strategy is an output of an engineered system that includes a business process, RASI, and a properly configured management information system (Maximo, SAP, etc) to ensure sustainability of the strategy. Continue reading

Rethinking the Decision Factory

by Roger Martin
Harvard Business Review

Companies everywhere struggle with the management of knowledge workers. They compete fiercely to find and retain the best talent, often accumulating thousands of managers in the process. For a while this is fine, but inevitably, usually when economic conditions turn less favorable, they realize that these expensive workers are not as productive as hoped, and in an effort to manage costs they lay off a large swath of them. Soon after, though, they’re out recruiting again. Continue reading

PLC: Programming in List on a Mitsubishi PLC – Part 2

by Jim Rowell

Last time, we pretty much ignored ladder diagrams. This time I’m giving you lots of them. We’ll look at the ins and outs of turning those pretty pictures into powerful text. You’ll gain insight into the block commands and the various structures that can be built using List. You’ll leave with full knowledge of the perils and pitfalls.

We’ll be using numbered as opposed to named I/O for the examples. Don’t get used to it and definitely don’t be discouraged by it. Numbers work best for showing you how the code works but they’re terrible at showing you what it’s actually doing. Your own code (with proper I/O names) will be much easier to follow. Continue reading

How to Build Your ISO 55001 Asset Management System Quickly and make ISO 55001 Certification Easy

from Lifetime Reliability Solutions

How to Build your ISO 55001 asset management system quickly and make ISO 55001 Certification easy: Enterprise asset management has an international standard: 55001 Asset management – management systems – requirements. It specifies what an organization’s asset management system must contain. Producing an ISO 55001 compliant asset management system leads you into a detailed, disjointed, demanding project. But there is a much simpler solution to design and develop a complying ISO 55001 EAM ready for ISO 55001 certification.

Click here for pdf file. (PDF: 1.6MB)