Advanced Machine Reliability Resources

Franklin, United States

Advanced Machine Reliability Resources

Franklin, United States

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Johnson M.,Advanced Machine Reliability Resources
Tribology and Lubrication Technology | Year: 2012

A North American wire manufacturer operating a multidrive, wire-drawing machine set implemented an inspection and machine condition-monitoring plan (including oil analysis) to improve plant productivity. The drives were evaluated for proper viscosity, and it was determined that the operating conditions justified the use of an ISO 460, which was in use at the time. Following a spike in wear conditions, a decision was made to convert worm gear sumps on one production line from the standing mineral oil-based gear lubricant to a PAG-based product at the equivalent (ISO 460) viscosity grade. Ensuing samples suggested that the wear conditions that occurred with the mineral oil-based worm gear lubricant were alleviated. Four sample cycles occurred since the upgrade to the PAG product type, resulting in a sharp and permanent decline in iron and copper.


Johnson M.,Advanced Machine Reliability Resources
Tribology and Lubrication Technology | Year: 2012

Ultrasonic analysis has become a popular way to tune and improve greased bearing lubrication. While machine condition analysis, including measurement for presence of a lubricating film, is useful in helping equipment owners determine the effectiveness of the lubricant film in machines with rolling contacts, ultrasonic energy measurement is useful in other ways. A discussion covers the bearing surface; rolling contact interaction; quality of the elastohydrodynamic oil film in oiled greased bearings; options for sensor placement and data collection; and common interferences contributing to signal loss when sound travels.


Johnson M.,Advanced Machine Reliability Resources
Tribology and Lubrication Technology | Year: 2012

High-frequency energy is produced when the naturally occurring asperities at two interacting surfaces collide under force. The impact creates a compression wave that propagates through the machine. There are different names for this energy medium, but in the end each represent a way to look at highfrequency energy production. As the number of asperity contacts increase (which coincides with the progressive loss of the oil film) the amount of measurable energy increases. There is a variety of interferences common to ultrasonic frequency collection, including material defects, differences in impedance and reflection/ refraction. With fundamentally sound data collection techniques that deliver dependable, repeatable data, reliability engineers can systematically measure for lubricant film formation or loss of lubricant films in some critical machines.


Johnson M.,Advanced Machine Reliability Resources
Tribology and Lubrication Technology | Year: 2012

Lubricant suppliers have often established intervals as a value-added service to their customers. This is biased toward lubricant health and focuses on the low end of the value offering available from the effort, i.e., the oil change. A discussion on options to consider before setting an oil sample frequency for machines covers the rate of progression to failure; machine criticality ranking; environmental stress rating; machine health status; frequency factors; baseline sample interval; and sample calculation.


Johnson M.,Advanced Machine Reliability Resources
Tribology and Lubrication Technology | Year: 2010

Lubricant, when properly selected and maintained, provides surface clearance that also enables effective energy use. This aspect of machine lubrication is overlooked, as is human energy use. A discussion covers the strong theory behind reduced better lubrication practices; how most plants could save huge amounts of money by improving their human energy use; and a six-step lubricant evaluation process that reduces energy consumption.


Johnson M.,Advanced Machine Reliability Resources
Tribology and Lubrication Technology | Year: 2010

The total cost of lubricant purchases is truly irrelevant to the plant's annual profitability. The differential cost between the stuff in use vs. the stuff that could be in use can sometimes by significant, but in the end, it is still irrelevant. High-performance lubricants offer the end-user the hope of lower total maintenance and/or energy costs. The general differences in conventional, high-performance and specialty products, as well as the impact of the net lubricant purchases on plat profits are presented. A comparison between use cost and purchase price is shown. The possible drawbacks that could accompany a switch to high-performance products are presented.


Johnson M.,Advanced Machine Reliability Resources
Tribology and Lubrication Technology | Year: 2010

Rate- of-change (ROC) and volume-compensation alarms, which are common process alarms that could be effectively used to track machine conditions operating under a variety of considerations are presented. When coupled with top-up volume normalization, ROC alarms may help the engineer make decisions about the lubricant's long-term surface protection characteristics, something difficult to track with routine lubricant-analysis processes. Aside from wear debris analysis, this technique also could be used to measure contamination control effectiveness for hydraulic and circulation systems and improve sump life- cycle management. Coupled with oil top-up volumes, this method could be used to gauge engine wear for large industrial engines driving ships, trucks and vehicles. Particularly, as it pertains to wear debris for engines, the small wear particle size in engine oil analysis is below typical OEM filter element capture size, meaning wear data should be well represented.


Johnson M.,Advanced Machine Reliability Resources
Tribology and Lubrication Technology | Year: 2010

Operation-based machine care, specifically lubrication care, has been a point of interest by senior management for many years but is still not a widely adopted practice for continuous process plants. A well-conceived plan, coupled with a firm commitment to consistently fulfill scheduled practices, can deliver the quality that is expected. A well-conceived plan will be inherently reliability-centered, machine-specific and will include stated goals and objectives that are both achievable and measureable. The plan begins with a machine review for detailed task development, review of material resources needed for the tasks in the plan and an appropriate allocation of time for completion. A planning and tracking system is designed around the tasks to enable routine tracking of multiple instances of multiple tasks/events with the minimum dependence on manual record keeping. Operator training is developed around the machine-specific tasks, routes and the tools for delivery. In addition to the obvious support from management's dedication of resources to the development of the practices, visible and vocal management support should be demonstrated through holding employees accountable for work completion.


Johnson M.,Advanced Machine Reliability Resources
Tribology and Lubrication Technology | Year: 2011

Contaminant monitoring and control is of paramount importance to machine productivity. Air, water and particulate (atmospheric and wear related) are dominant contamination threats to industrial machines. Using techniques that clearly diagnose each threat and setting specific responses to each exception is at the heart of defect elimination and condition improvement for industrial machines. It is useful to drive these diagnoses to the shop floor and assign condition monitoring technicians the task to use available technologies to make quick and dependable decisions. There are many options to choose from covering all three points of interest. Laboratory testing is typically more quantitative, takes longer and provides for stronger long-term trending of data for pattern diagnosis. At a minimum, lab-based analysis done following recorded exceptions from shop floor analysis is essential to a healthy program.


Johnson M.,Advanced Machine Reliability Resources
Tribology and Lubrication Technology | Year: 2013

As stated at the beginning of this article, for roughly $500 in hardware and the cost of consumables, a machine can be fitted for a lifetime of better care access. When one considers the amount of production that a given machine is responsible for, the dollar value is irrelevant, and this decision should proceed on variable capital or with expense money. Resistance to do so is not an economic decision. It may be an academic decision, but, if so, this can be remedied with simple explanation of the consequences of moisture, air and particulate in the oil. Collaboration may be warranted for the work culture, and, if so, that will take time. Beyond this, the only reason that management should not wish to pursue something that is fractions of a penny per year of expected production value is that the reliability community didn't get the attention of the key manager for long enough period of time to make the case for improvement. We just didn't make the case!

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