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Learning Sessions
3 Keys to Driving Sustainable Change and Project Success
Bruce Wesner, Life Cycle Engineering
Have you ever been the leader of a significant business change and not been able to make it stick? Most organizations feel that the key element in any project is sound project management, but what about the people it is affecting? This presentation will focus on the essential elements required in effectively managing a business change initiative to ensure it is sustainable.
7 Common Traits of Winning Maintenance Reliability Programs
Terrence O'Hanlon, Reliabilityweb.com
There are common traits to every high-performance maintenance reliability program, and what separates the most successful ones from the others is usually only a slight advantage in one of a few key areas. In this session, find out all the important details about award-winning reliability programs so you can implement similar processes and procedures in your program and match their success.
8 Steps to Achieving Operational Excellence
Kevin Duggan, Institute for Operational Excellence
The ability to implement and maintain improvement initiatives like lean and Six Sigma is essential for eliminating waste, reducing costs and increasing output, but what often results is an improve-sustain-improve-sustain pattern. Rather than endure a never-ending journey, this presentation will show attendees how they can "jump" their improvement efforts and grow their business simply by setting a destination of operational excellence. Learn the step-by-step process for achieving operational excellence to facilitate real business growth in any industry.
A Structured Approach to Training and Development for Reliability
Bill Lyons, Holcim US
This presentation will discuss the benefits of using a structured approach for training and the development of skills for reliability. A cement manufacturer recently made great progress with its maintenance technical training program and certification, and this session will describe how it was done so others can implement a similar type of program at their organization. Attendees will learn about all areas of reliability in place of just lubrication, even though lubrication is the main and perhaps most important of all the reliability areas.
Accelerated Inductively Coupled Plasma Analysis of Wear Metals in Oil
Michael Sgroi, CETAC Technologies
Inductively coupled plasma (ICP) techniques can be utilized to more efficiently run oil samples in order to determine wear metal and additive element concentration. This presentation will detail the analytical tools that help laboratory personnel automate the process of oil sample preparation and how to accelerate the automated analysis. Attendees will discover what happens to oil samples that are taken out of equipment, the overall laboratory process that a sample follows and how samples are analyzed to determine which wear and additive elements are present.
Achieving Labor Excellence in Maintenance and Lubrication
Alejandro Meza, Innovalube
The lack of a formal developmental plan to achieve labor excellence still exists today even in some leading companies, particularly for lubrication- related functions, and can result in poor performance. This session will explain why it is important for the lube team to be aware, qualified and motivated, as well as have the ability to use technology and other resources to succeed on the job. Attendees will learn the factors involved in attaining labor excellence, how to assess and improve the current conditions at their work location, the value of training and development for qualified work, and the need to allocate resources and have managerial support to implement a developmental plan.
Advanced Gas Turbine Reliability Issues and Management
Syed Ahmed Nadeem, Pakistan International Airlines
Gas turbine maintenance costs are a big problem, especially with regard to hot section parts replacement and the performance of high-temperature alloys. The operating practices are typically aligned with turbine design limits. This session will explain the importance of a reliability program for gas turbines, material upgrades for power generation turbines, hot section failure analysis and the concept of reliability- centered maintenance as applied to gas turbines. Attendees will learn modifications and upgrades, best operating practices, assessments for life- extension evaluation and recommendations for gas turbine reliability issues.
Air Seals: An Alternative to Packing
Tom Horner, Inpro/Seal
Although it is known to damage shafts, packing continues to be widely used in rotating equipment. It also involves a fair bit of maintenance, which takes up valuable time. Additionally, there is the cost of flushing the packing. This can be done with water, but in most cases a product like a light gas oil may be used, especially in refineries. Flushing can become very expensive when a finished product is used. This presentation will focus on the alternatives to packing, including mechanical seals, contact seals (lip and magnetic) and air purge seals, as well as the features and benefits of these options.
Alignment and Installation Factors that Impact Machine Reliability
Steve Lochard, Ludeca Inc.
Precision alignment is a necessity for keeping machinery running at optimal conditions. Many times machinery bases are not flat and coplanar relative to the machinery feet and centerline. It is critical to realize the proper alignment targets so shafts will be aligned during running conditions. Attendees of this session will become aware of the importance of precision alignment, machinery base and feet flatness, and the development of alignment targets to result in properly running machines that generate less vibration, noise and operating costs.
Alternatives to Traditional Oil Testing Methods
Susan Benes, ASPEX Corporation
Many people are not aware of the limitations of current oil testing methods like ferrography and inductively coupled plasma (ICP) spectrometry. This session will highlight these limitations and provide comparison data for existing methods and for scanning electron microscopy (SEM) and energy dispersive X- ray (EDX) testing. Attendees will learn how SEM/EDX works and how it compares to more traditional oil debris testing.
A Practical Guide to Developing KPIs
Paul Lanthier, Carver PA Corporation
Key performance indicators (KPIs) are an essential part of managing processes and ensuring the desired benefits are achieved today and for the long term. While most organizations put significant emphasis and effort in developing KPIs, many find it difficult to quantify the benefits achieved by their use. This session will discuss the various types of KPIs, simple rules for choosing and managing them, how to develop a KPI hierarchy and using factors to qualify their importance.
ASTM's Efforts to Improve Condition Monitoring
Greg Livingstone, Fluitec, and Bryan Johnson, Arizona Public Services
As a global leader in the development of standards, ASTM has been creating standards for petroleum products and lubricants for more than 100 years. The organization currently has almost 600 active standards that are used throughout industry. This presentation will summarize how ASTM's efforts are improving condition- monitoring practices and will discuss several new standard initiatives that are currently being developed. Attendees will get a glimpse into the latest developments in oil analysis testing and learn how to use these latest standards and guidelines to improve their condition-monitoring programs.
Complete Guide to Starting a Lubrication Program
Jeremy Wright, Noria Corporation
For those who have been thrust into a position as a lube champion but don't know where to begin, this session will discuss how to kick-start your lubrication program to ensure future success. From quality lubricants and lubrication to metrics and analysis, contamination control, and people and training, discover all the key components that go into creating an effective lube program.
Building the Business Case for Maintenance Planners
Andy Gager, Life Cycle Engineering
A good maintenance planner can have a significant impact on the bottom line, yet many companies don't pay adequate attention to this role. With 18 percent of a typical maintenance technician's day spent looking for parts and 24 to 26 percent walking to and from the job site, almost 50 percent of each day can be wasted doing non-value-added activity. This session will address the financial impact of maintenance planning on an organization and will provide a clear understanding of how to improve this function and yield better results.
Case Studies in Contamination Control at Mine Sites
Christian Bauer, Pall Corporation
From drilling and blasting to hauling and loading, mechanical and metallurgical processing, as well as environmental protection, effective contamination control in mining processes is essential for achieving and maintaining the required levels of fluid system cleanliness and factors into a mine's operating cost. In this session, learn how implementing a contamination control program, including cleanliness monitoring and the use of high-efficiency filtration, can help operations that are prone to a high contamination environment improve reliability and productivity.
Case Study: What You Can Learn from a Single Machine Failure across Your Site
Brian Blyth, DuPont Louisville
Many plants have long-standing predictive maintenance programs such as oil and vibration analysis that over time can become less effective without basic upkeep. This presentation highlights some of the neglected parts of those programs and presents a case study on improvements that were made after a single refrigeration machine failure. Attendees will learn basic root-cause failure analysis and failure-mode-and-effect analysis techniques and how to leverage this learning across an entire site to deliver cost savings as well as high reliability.
Changing Maintenance Professionals from Parts Replacers to Diagnosticians
Dale Constantine, Step Energy Services
With the increasing competition in the marketplace, maintenance must look at repairs and services differently. Preventative and predictive maintenance systems should be examined, and repairs viewed as opportunities to find the root cause and return equipment back to a timeline based on PMs, not just removing and replacing parts. We have created an environment of maintenance professionals who have been taught how to replace parts and not on root cause and post-failure strategies. We must undo years of training and develop maintenance professionals who are more at home with calculators, micrometers, thermo-imagers, vibration tools and oil sample reports. All the greatest equipment and ideas are meaningless if the final caretaker is not trained, supported and coached at being a diagnostician rather than a parts replacer.
Two-Tiered Predictive Maintenance Programs for Multiple Plant Organizations
Jack Nicholas, Brent Miley and John Shinn, Metropolitan Sewer District of Greater Cincinnati
A two-tiered predictive maintenance (PdM) program can improve team member productivity and employment for organizations with multiple plants. PdM team members serving widely dispersed plants are often unable to provide adequate coverage. This problem can be eased if local repair personnel are provided with simple, easy-to-learn PdM tools that can confirm when a problem exists, even if its exact nature cannot be determined until a team member is called to the site. Cooperation between PdM team members and repair personnel can be developed so that overall maintenance effectiveness is enhanced. In this session, attendees will learn the details for setting up a two- tiered PdM program, including the benefits, frequently encountered problems and technologies employed at each level of the program.
Conditioning and Regeneration of Ester-Based Fluids
Steffen Nyman, C.C.Jensen
More and more industries are changing to ester- based fluids due to environmental or fire-hazard concerns. However, ester fluid is not your typical hydraulic or lubrication oil. It requires special care. A poorly maintained ester fluid will have a very short life and will result in expensive component failure and costly downtime. If fluid contamination is controlled, many ester- based fluids can be in operation for decades. This presentation will describe the pros and cons of ester fluids, how ester- based fluid degrades, and how the ester can be conditioned/regenerated to prolong its service.
Creating Mixed Model Value Streams
Kevin Duggan, Institute for Operational Excellence
Today's factories are often complex with shared resources, product variations, uncertain demand from day to day and lots of tailoring for customers, making it challenging to run a mix of products through the same value stream. This session takes the concepts of value stream mapping to the next level, describing a method for creating flow in factories that have a high complexity of products, demand and shared resources. By learning how to apply lean principles in a high-variety environment and understanding product family selection, attendees will know which techniques to use when faced with difficult situations, including high product mix, scheduling problems, shared resources and unstable customer demand.
Effective Enterprise Asset Management Master Planning
Mike Greenholtz, GenesisSolutions
Enterprise asset management (EAM) in capital-intensive industries provides a major opportunity for improving equipment availability, operating performance and financial results. Effective EAM addresses the elements of the equipment lifecycle from conceptual design, manufacture, construction, commissioning, operations and maintenance through decommissioning and retirement. EAM includes computerized maintenance management systems (CMMS) and associated databases needed to support total lifecycle management of assets, as well as the associated business processes and key metrics required to govern the entire program. This session will cite real-world examples of the benefits that can be achieved through the deployment of an effective EAM program, including bottom-line improvements, a blueprint for continuous improvement principles on reliability efforts, examples of how this method can work and how to gain executive endorsement.
Efficient Real-World Contamination Control of Hydraulic Fluids
Dan Zoller and Glenn Bauernfeind, Schroeder Industries
Contamination control is an important part of operating and maintaining hydraulic systems. Substantial cost savings can be achieved through proper fluid conditioning and monitoring along with the effective use of fluid treatment equipment. This presentation will outline strategies to improve fluid condition and consequently extend the life expectancy of hydraulic fluid and equipment while also exploring the development of an efficient real-world method of controlling and maintaining acceptable contamination levels.
Environmentally Safe Lubricants in Industry
Mark Miller, Terresolve
While many operators want to use environmentally preferable technology, there is much confusion over the various types and their respective performance characteristics. This presentation will provide a no- nonsense approach to environmentally safe lubricants to help you choose the right fluid for the right application. Attendees will learn the various definitions of "biodegradable," the strengths and limitations of each product type, and the maintenance practices required to prolong the life of the fluid and the equipment. Water infiltration, high pressure, wide temperature range usage and ways to manage these challenges will also be discussed, along with environmental fluid compatibility with hydraulics, pumps, sealing materials, hoses and other important components.
Expectations vs. Reality: How Well Does Your Filter Perform?
Christian Bauer, Pall Corporation
This session will explain why you should look beyond the filtration ratio as the primary indicator of filtration performance in the context of fluid system cleanliness specifications and requirements, as well as provide answers and insights to the following questions: "Do we know how well a filter is performing over the course of its service life?" "Will a filter that is nearing its changeout differential pressure still adequately protect the fluid system in which it is installed?"
Food-Grade Lubricants: What You Need to Know
Toby Porter, Kluber Lubrication North America L.P.
As the machinery in the food, beverage and pharmaceutical industries continues to improve, it is important that your lubrication program keeps pace. Increasing production demands, risk analysis programs, etc., pose significant new challenges for maintenance managers, and lubrication can sometimes be overlooked in the larger picture of manufacturing reliability. The lubrication of necessary components must take into account the improvements of these industries, while also maintaining safety in cases where incidental food contact is a possibility. Understanding these variables is crucial to the creation of an optimized lubrication program.
FRACAS – Anatomy of a Failure
James Taylor, Machinery Management Solutions
One of the most difficult steps in failure analysis in a facility or industrial setting is capturing good data about the failure. This presentation explains how to capture and store that data either automatically or with minimal effort. The data can then be used to support failure analysis and corrective action. This session will also look at the scene of the failure and discuss ways to collect the right physical and subjective evidence.
FTIR Spectroscopy – A Misunderstood Lubricant Analysis Tool
Dave Wooton, Wooton-Consulting
Fourier transform infrared (FTIR) spectroscopy has been used for analyzing in-service fluids for more than 30 years. Today, there are a dozen ASTM standards designed around FTIR spectral data for characterizing in-service fluids. Most in-service test programs include FTIR spectral data as part of the monitoring program. However, very few of these programs actually use this data, which is often misunderstood, misinterpreted or misused. This is due to the complexity of the data generated and the lack of proper training on the technique. This presentation will discuss how FTIR spectroscopy should be utilized, including current practices, available techniques and advanced applications.
Getting to Effective Preventive Maintenance
John Crossan, John Crossan Consulting, and Randy Quick, Kerry Ingredients and Flavors
Many plants continue to perform maintenance in a mostly reactive mode where it seems impossible to find the time and staff to get the essential preventive maintenance (PM) work done that would enable them to move toward the world of proactive maintenance. This presentation will describe methods for making preventive maintenance effective in moving from reactive to proactive maintenance, along with the most common reasons for failure and ways to avoid them. Attendees will learn the importance of constant training and education mechanisms, having dedicated time for preventive maintenance, and developing ownership and participation by all.
Grease: Filling the Void
Lisa Wadlington, Shell
Grease is often the most overlooked, underutilized and misunderstood of all the lubricants. This presentation will explore the facts and applications for grease to help get your plant rolling along smoothly. Attendees will discover how to determine if you are using the correct grease for the application at hand, proper greasing techniques, best practices for storage and handling, and the benefits of single-point lubrication.
How a Proactive Fluid Analysis Program Can Save Money and Extend Equipment Life
William Willis Jr., On-Site Analysis, Inc.
Through the years numerous studies have documented the benefits of a condition-based preventative maintenance program. This session will detail how a proactive fluid analysis program can actually pay for itself, generate significant operation savings and increase service-bay throughput. Case studies will be presented for truck service providers, truck fleet operators, mining operators, municipalities and industrial users demonstrating the specific advantages of fluid analysis, such as a reduction in unscheduled repairs, elimination of engine-related breakdowns and extension of the useful life of the equipment.
How Clean Fluid Can Extend Component Life and Provide Cost Savings
Eric Miller, Petrolink USA
This session addresses the importance of fluid cleanliness in extending component life and the cost savings associated with systems operating at optimum cleanliness levels. Attendees will learn the importance of particle count analysis to monitor fluid cleanliness and how to interpret the particle count analysis results. This interpretation will allow the maintenance professional to know when and what measures should be taken to keep the system fluid at the optimum cleanliness level and therefore realize maximum cost savings by reducing the cost associated with replacing equipment and the downtime it creates.
How to Choose the Right Oil Filter
Wes Cash, Noria Corporation
Filtration is key to prolonging the life of your equipment, but are all filters created equally? Not all filters behave the same way in service, so understanding how they work is important when deciding what filter to use. This session will explore what you should consider when purchasing filters for use in different machine types as well as look at what makes some filters better than others.
How to Design a World-Class Lube Room
Mark D. Jones, Lubrication Engineers
Since very few people know how to properly design a lube room, this session will detail a step-by-step approach to create a world-class lube room. Attendees will learn what it takes to plan, build and execute a lube room, as well as understand the importance of consolidating lubes, color coding, spill containment and how to decide whether to use plastic or metal.
How to Efficiently Remove Varnish
Felix Michold and Axel Wegner, C.C. Jensen
Many industries are experiencing varnish-related problems. These problems occur frequently in power generation, and the consequences can include turbine trips, high maintenance costs, loss of revenue and even penalties when varnish strikes. During this session, attendees will learn how to remove varnish efficiently and avoid varnish-related failures, reduce operation and maintenance costs, prevent unnecessary oil changes and achieve maximum oil lifecycles. Several practical case studies will be presented, including one with a leading energy company.
How to Identify Root Causes of Lubrication Failures
Jorge Alarcon, IK4-Tekniker
According to recent studies, many maintenance problems are due to lubrication failures. While it can be difficult to classify these failures, it is important to find a pattern that enables the identification of the reason for the failures. This session will present an approach that is the result of five years of study and based on real cases in industry to help determine the causes of lubrication failures. Attendees will learn through actual case studies how it is possible to identify the root cause of failure.
How to Select Heat Transfer Fluids
Gaston Arseneault, Petro- Canada Lubricants
Although many plants operate heat transfer systems, the number of people with in-depth knowledge of these systems is diminishing. End users must realize that while they sample 5- gallon gearboxes, they may have hundreds of gallons of heat transfer oils that go unchecked for years. This presentation will discuss the various types of heat transfer fluids, including their basic properties and modes of degradation, as well as describe how to properly select them, instead of just focusing on price or one test result.
How to Select the Right Lubricant for the Right Application
Anoop Kumar, Royal Manufacturing
Most end users do not know how to read and analyze a lubricant supplier's product data sheet in order to make the proper selection of lubricating greases. This session will explain how to distinguish data from different suppliers so you can choose the right product for your application. Attendees will learn the basics of lubricating greases, what properties to look for and when to use oil or grease lubrication.
Implementing Reliability into Assets through Predictive Maintenance and Lube Excellence
Ken Hughes, Power Partners Inc.
Applying lean methods such as reliability-centered maintenance (RCM), total productive maintenance (TPM) and lube excellence can help any organization attain continuous improvement and transform its facility from reactive to proactive maintenance. This session will show attendees where to focus to achieve the goal of reduced downtime for their plant as well as explain the process to improve the maintenance storeroom, how to apply predictive maintenance tools and why 7S is important.
Integrating Operations and PdM into a Comprehensive Reliability Strategy
Jeff Evans, Maintenance Strategies Inc
Many organizations have numerous programs and processes for managing assets, including the use of various predictive maintenance (PdM) technologies, operational inspections, equipment testing, etc. With all of this data, companies often struggle with how to integrate this information into a comprehensive plan that is focused on improving reliability and optimizing asset performance. This session will outline strategies used to improve operations at a large utility, how mobile devices were introduced and how operational activities were integrated with other PdM activities to create an integrated asset health approach.
iPads in the Workplace
Tim Chaten, GTI Spindle Technology Inc.
Apple's iPad is an incredible multi-touch computer with uses that most people overlook, including as a productive tool in the predictive maintenance workplace. This session will discuss various apps, accessories and workflows for using the iPad at work. Attendees will become empowered to use something they already have access to while learning ways to protect their iPad in the workplace, accessories and apps that allow vibration analysis to be done on an iPad, and methods of balancing spindles using apps alone.
Lube Manuals Should be more than Catalog Cut Sheets
Jerry Putt, Noria Corporation
The lube manual should be a key document that provides a roadmap to achieving the optimum level of lubrication for equipment. The designer can use the manual to convey key information that may not be obvious once the equipment is installed. This session will discuss what the designer should include and how it might be implemented by the equipment maintainers.
Lubricant Deposit Characterization
Dave Wooton, Wooton- Consulting
A growing performance problem with in-service lubricants is their generation of deposits. In most cases, lubricant deposits are referred to as varnish and are thought to all be the same. In reality, deposits have a wide range of different chemistries depending upon the formulation of the lubricant, the application, the mode of degradation and interaction with contaminants. This presentation will discuss the current state of varnish deposit characterization and how this can be the root cause determination pathway.
Lubricant Deposit Characterization Case Studies
Greg Livingstone, Fluitec, and Bryan Johnson, Arizona Public Services
Properly characterizing a lubricant deposit can provide insight into the cause of a problem and allow plants to make corrective actions, resulting in tremendous savings. This presentation will present a multitude of real-world case studies where this practice of deposit characterization has been used in the field. Attendees will learn how a unique deposit that is not detectable through normal varnish testing caused a million-dollar shutdown at a nuclear facility, about the creation of tar balls in a sensitive gas turbine, how black goo was generated in a critical gas compressor, among others.
Lubrication: An Exercise in Continuous Improvement
Ted Melencheck, Cargill Deicing Technology
When lubrication moves from being a program to a process, significant gains in cost reduction and reliability can be achieved. This case study presentation will demonstrate the value of establishing a fundamentally sound lubrication initiative that will serve as a foundation to build improvements through incremental steps. In addition to integrating data evaluation and interpretation, the use of root cause analysis will show how problems can be reduced or eliminated through a continuing improvement processes. This will be illustrated with case studies from real-world situations that can be easily related to many industries. Attendees will learn how to develop and manage lubrication initiatives, the importance of oil analysis and the use of reference samples, as well as how improvements can be made one step at a time through technology, employee engagement and commitment.
Maintenance Key Performance Indicators: You Can't Manage What You Can't Measure
Darrin Clark, ArcelorMittal USA
Reliability improvement initiatives often struggle to sustain progress. However, key performance indicators (KPIs) are quite effective at maintaining focus on the needed activities to drive improvement to a maintenance organization's performance. In this session, attendees will learn the importance of aligning KPIs to the business process, the difference and link between leading and lagging indicators, and how to deploy KPIs both vertically and horizontally in a large organization.
Managing Risk from Transformer Failures
Alan Ross, SD Myers
The reliability of a system is only as good as its weakest link. In recent years, the transformer, considered the heart of the electrical system, has increasingly become that weak link. Many production systems rely on transformers that have far exceeded their planned useful life. So what is a reliability expert supposed to do when an essential part of his system is for all intents and purposes beyond practical life expectancy? This presentation will examine the common mistakes organizations make when it comes to transformer management, including case studies and expert insight.
Monitoring Cleanliness Levels in Hydraulic Systems with the Mesh Blockage Method
Eric Krause, Pall Corpration
Monitoring hydraulic system cleanliness levels through particulate contaminant analysis is fundamental to achieving system reliability. However, automatic particle counting using light extinction technology is sensitive to optical interference caused by conditions such as non-homogenous fluids, free water in the system and air bubbles. These conditions can yield erroneous data and result in incorrect conclusions and excessive maintenance costs. Fortunately, a mesh blockage monitor can provide significant advantages over the light extinction method. This session will explain the differences between light extinction and mesh blockage for evaluating fluid cleanliness levels in hydraulic systems, as well as how to use the mesh blockage method in field applications.
Monitoring Low RPM Bearings
Larry Goodenow, SPM Instrument
Monitoring low RPM bearings with traditional techniques is difficult at best, and some would say next to impossible. This presentation will detail a groundbreaking solution to the problems involving condition measurement on low-speed machinery. The new technology has been used successfully on all types of machinery operating from 1 to 20,000 RPM and sets a new standard for modern condition monitoring. Attendees will learn how slow-speed bearing failures catch most users by surprise and that many of these bearings are large bore types and not stock items, resulting in long lead times. The new technology is designed to reduce this lead time.
Motivating the Troops: How to Increase Employee Engagement
Diane Closser, Closser Lubrication Services, and Tom Hiatt, Covance
Employees in workplaces where overall engagement is high are more satisfied with the kind of work they are doing, experience higher levels of teamwork, feel more valued and recognized, and are less likely to be searching for a higher paycheck. This session will discuss where to start and how to get the best return on investment in making your company one of the better places to work. Attendees will be able to take ideas from this presentation and develop their own employee engagement team to address these issues at their plants.
Oil Analysis Case Studies: When Routine Tests are not Enough
Cary Forgeron, Analysts Inc.
Many people are lured into a false sense of security when their oil analysis report tells them everything is "normal." However, what they fail to understand is that some harmful condition may exist that was not included in the testing. This presentation highlights case studies where abnormal machinery /lubrication conditions existed but were not originally detected, as the proper analysis was not being performed. Learn the limitations of routine tests, how to identify advanced testing, and when and why to request advanced tests.
Oil Analysis Report Interpretation
Matthew McMahon, TestOil
An oil analysis report is a vital tool for a smooth-running operation. Without a solid grasp of the underlying principles of reading and understanding these reports, the inexperienced reader is likely to become frustrated with trying to make sense of the seemingly unintelligible test data. This presentation will explore report interpretation, explain how to read test reports, describe some of the most common tests run on industrial equipment, discuss marginal and critical reports, and detail how to decipher various alarms.
Oil Analysis Results from Primary Contamination Types
Aaron Black, Polaris Laboratories
The primary source of lost revenue due to equipment downtime is commonly a direct result of some type of contamination, be it dirt, water, product, incorrect lubricant or a combination of these. Oil analysis testing can identify these contaminants, but unless you are aware of the actual problems that can arise from them, it is difficult to take the correct action. This session will review the primary contamination types and explain why they cause such problems, as well as delve into what these look like from an oil analysis perspective when they are in your system.
Oil Monitoring as a Tool to Optimize Hydraulic/Lubrication System Performance
Mrinal Mahapatro, Pall Corporation
The presence of water in hydraulic/lubrication systems can lead to a reduction in the service life of hydraulic/lube fluids and also be detrimental to various system components including valves, bearings, gears, pumps, etc. This session will discuss the benefits of an oil condition monitoring program on fluid cleanliness and system operation and reliability, as well as how vacuum dehydrators function to remove water from oils.
Planning and Scheduling: A Best Practices Overview
Matt Midas, GenesisSolutions
What is the true purpose of your maintenance technicians? What do they spend the majority of their time on? You may be surprised. Often it’s not true maintenance activities, i.e., wrench time. Eliminating non- value-add time (searching for parts, getting approvals, looking for procedures and job plans, etc.) from a maintenance technician’s daily tasks is a strategic goal that can lead to improvements in efficiency, reduced downtime, improved safety and maintenance excellence. This session will describe elements of an effective planning and scheduling program, basic building blocks to establish a planning and scheduling function, how to gain executive sponsorship/endorsement and achievable benefit examples as a result of a successful program.
Preventing Ingress Contamination with Bearing Cavity Pressurization
Henry Dombroski, Air-Tight LLC
For anyone who has bearing contamination issues and has tried everything to resolve them, this presentation will discuss alternative methods for preventing ingress contamination. Attendees will discover how to stop bearing cavity ingress contamination by means of hermetically sealing the bearing cavity, pressurizing the cavity with low air or nitrogen pressure, controlling the pressure in the cavity 24/7, and obtaining a visual indication of the amount of pressure and of the bearing cavity integrity.
Process Analysis: Your Path to System Knowledge
Harold Joyce, PdMA Corporation
How well do you know your system processes? Can you identify the process behind every load variation on each motor in your system? This presentation will explain how to utilize process analysis to achieve motor and system reliability. Attendees will learn detailed analysis techniques for circulating water pumps and motor-operated valves as well as how to apply electrical fault zone analysis principles.
Process Performance Optimization: Combining Reliability, Lean and Change Management
Bruce Wesner, Life Cycle Engineering
Today, leaders of organizations are stretched to do more with less. They are asked to cover more areas with fewer resources, less time and smaller budgets. Given these constraints, how can you continue to drive improvement and achieve success? Focused improvement efforts can provide significant bottom-line impact. This presentation will show how reliability, lean and change-management best practices can be leveraged together in order to increase process performance.
Protecting Your Machine Surfaces from Chemical Attacks
Wes Cash, Noria Corporation
It is a well-known fact that particle contamination damages machine components, but what about other forms of degradation? If not properly monitored, lubricants can cause corrosive damage to these surfaces in a variety of ways. During this session, you will learn what to look for and understand how to make sure your oil isn't harming the equipment to which you are adding it.
Put New Life in Your Oil Analysis Program
Bob Scott, Noria Corporation
Walk through the components of an oil analysis program and gain some ideas on how to update and improve your existing program. This presentation will discuss selecting equipment based on criticality, choosing a laboratory, gaining awareness of how your laboratory bills you, understanding alarms and limits, test selection, data handling, sampling, reporting, interpreting data and program performance tracking.
Rapid Analyses for Fuel and Antifreeze in Used Engine Oil
Timothy Ruppel, PerkinElmer
If left unchecked, the presence of fuel and ethylene glycol in used engine oil will cause premature engine failure and loss of engine productivity. Routine analysis for these contaminants can predict engine problems, allowing for preventative maintenance before engine failure causes more costly consequences. High throughput automated analysis takes less than 2 minutes per sample, while older methods require 45 to 60 minutes per sample. This session will describe two separate analyses for the determination of contaminants in used engine oil that are more sensitive, accurate and faster than other methods currently used.
Reliability Analysis: Adding Value to a Predictive Maintenance Program
John Pucillo, Predictive Service, and Scott Sutfin, Kaman Industrial Technologies Corp.
Most predictive maintenance programs function fairly well with regards to identifying impending issues and addressing them with corrective measures. However, many programs fail to identify trends that would help reduce or eliminate problems from reoccurring. The majority of these issues are created or amplified from a lack of precision in the maintenance effort. This session not only will describe how to identify failure modes, but also how to capture and trend them for periodic analysis. Through this Pareto analysis method, item-effecting production, quality and availability can be identified and strategies put in place for improvements.
Reliability as a Service: How Cloud Computing has Moved into Predictive Maintenance
Tim Kelley, Azima DLI
Cloud computing continues to sweep through many industries. Condition monitoring and predictive maintenance are no different. It's clear that cloud computing is here to stay, and companies within the manufacturing and energy industries are well positioned to reap the business benefits such as cost savings, increased operational efficiency and improved quality of service. This presentation will discuss the advantages of investing in cloud-based condition-monitoring programs and walk attendees through the necessary steps for deployment.
Secrets to Achieving Lubrication Excellence
Jeremy Wright, Noria Corporation
Have you ever wondered what industry leaders are doing and what makes them the leaders? In this presentation, the five main attributes of world-class organizations will be revealed. You will also learn what many companies do wrong when trying to transform to lubrication excellence so you can be sure to avoid the same mistakes and reap the benefits of becoming a top performer in the lubrication field.
Simple Ways to Monitor Lubricant Condition
Bennett Fitch, Noria Corporation
While oil analysis is the preferred method for lubricant condition monitoring, some issues can still go unnoticed or aren't caught quickly enough. Lubricants and the machines in which they are used can provide subtle clues. Technicians who are frequently around their machines sometimes have gut feelings when something is wrong. With a few simple techniques and your five senses, learn how to catch faults quickly when all else fails.
The Benefits of Proactive Lubrication
Dale Jones, Allegheny Wah Chang
Learn how to start applying lubrication best practices and enforce these concepts to get a significant payback. This session will feature real-time case studies with filter-patch images, particle counts, documented cleanliness improvements and real-life cost breakdowns that show the financial benefits of these activities. Understanding the value of a proactive approach to contamination control will allow you to attach a dollar amount to improvements and present them to management in a way that is sure to get favorable attention.
Tools for Successful Reliability Partnerships
Ward Bond, Covance Inc.
Selecting the right reliability services vendor can make or break a successful reliability program. When considering the options available to those with reliability needs, a tool for evaluating the application and fulfillment of potential vendor qualities can improve the fit of the vendor to the service desired. This presentation will provide unbiased information that will aid attendees in selecting the best vendor for their individual needs, including examples of real-world applications of vendor selection and evaluation matrixes, as well as how the use of these tools can lead to successful reliability vendor partnerships.
Transforming Lubrication Procedures to Best Practices
Daniel Rader, Oklahoma Gas and Electric
This case-study presentation will detail how a power plant in Oklahoma went from standard operating procedure for oil lubrication to world class. Attendees will learn how a lack of lubrication standards, higher incidence of equipment failure and minimally trained maintenance personnel can be transformed to best practices in lubrication with fewer equipment breakdowns and an empowered maintenance staff. This session will also highlight the importance of vibration technology, oil sampling for predictive maintenance, proper lubricant storage and handling, and expert training.
Using a Team Approach to Achieve Maintenance Excellence
Ray Ardahji, Toyota Boshoku America
This session will explain how a collaborative approach between operators, technicians and engineers can empower production staff to conduct minor maintenance activities. With the Autonomous Care (AC) process, operators become an integral part of machine reliability and maintain their own equipment through daily inspections, lubrications, detecting abnormalities and quality checks. The result is fully restored equipment conditioned to its ideal state, along with the establishment of basic conditions for maintaining it and preventing equipment deterioration. Properly implemented AC reduces the causes of 30 to 50 percent of unplanned downtime, freeing skilled trades for higher level specialized activities.
Using Root Cause Analysis as a Proactive Tool
Bob Latino, Reliability Center Inc.
Why do you have to wait for bad things to happen to use root cause analysis (RCA)? Why can't you do RCA on unacceptable risks or chronic failures that do not rise to the severity of a regulatory event? This session will explore how to use failure modes and effects analysis (FMEA) and opportunity analysis to quantifiably measure the impact of failure over time and determine the significant few (the 20 percent of the events costing you 80 percent of your risk and/or dollar losses). In this fashion, you are using RCA proactively to provide an actual, measurable return on investment (ROI) that will quickly and dramatically improve operational reliability.
Using Surface Technology to Extend Equipment Lifecycles
Ricardo Hein, Conexo
The mechanical component lifecycle is affected by wear and damage processes in acting surfaces. Prematurely failing components not only have a far-reaching economic impact on operators but also a consumptive impact on the environment. This greater need for resources affects the sustainability of the operation. However, by utilizing nano-tribological metal treatment, you can extend component lifecycles through a reduction in surface roughness and friction. This provides an opportunity to change predictive maintenance as we know it and turn it proactive to avoid machine stops and make equipment repairs without downtime.
Using Thermal Imaging to Diagnose Machinery Lubrication Problems
Leith Hitchcock, RAM-C
Diagnosing machinery lubrication- related issues with thermal imaging is a technique that is not widely understood or used in conjunction with lubrication management, despite being an extremely powerful method when used as part of an overall program. This session will cover the principles of thermography, including applications and limitations of the technique, as well as its ability for integration with other condition monitoring techniques and its use as part of a lubrication management program. Extensive case histories of thermography applications for diagnosis of lubrication problems will be provided.
Using Ultrasound- Assisted Lubrication
Adrian Messer, UE Systems, Inc.
Most premature bearing failures are the result of lubrication- related problems, and the majority of plants and facilities struggle with these types of issues. By using ultrasound, you can help to reduce over- or under-lubrication of bearings. The trend is toward more condition- based lubrication rather than time-based lubrication. In this session, you will learn how ultrasound technology can be utilized to assist current lubrication practices, including data collection and analysis, as well as hear sound examples of bearings in the process of being lubricated.
Viscosity Selection Using Viscosity-Temperature Graphs
Bob Scott, Noria Corporation
After particles and water, the wrong viscosity is a leading cause of equipment failures. Viscosity-temperature graphs illustrate the change in viscosity as the temperature changes and can be very useful for selecting oils. This session will explain how to create viscosity-temperature graphs, as well as how to read them and utilize this information to choose the proper ISO grade of oil.
What You Should Know About Lubrication and Seal Compatibility
Greg Kayes, Kluber Lubrication North America L.P.
The way sealing rings and lubricants interact is critically important in the function and life expectancy of any drive unit. A major factor in the durability of a seal is the combination of the sealing material and the lubricant used, which so far has received little attention in the design of gears. To keep friction and wear to a minimum, the radial shaft seal and the lubricant must form a functional unit. The lubricant should form a separating film in the bearing, the teeth and at the sealing tip. This reduces friction, increases the gears' efficiency, improves the dissipation of heat and protects the components against corrosion. This session will explain how the reliability of machines and drive units can be significantly improved and their lifetime extended by considering lubrication and seal compatibility.
When Are Mineral Oils Superior to Synthetics?
Bennett Fitch, Noria Corporation
It is common knowledge that synthetic lubricants have advantages over mineral oil lubricants. However, this may not always be the case. Understanding the key differences between synthetics and mineral oils can provide clues as to when each should be used in order to get the most out of your lubricant. This session will discuss the important characteristics of synthetics and mineral oils as well as how to utilize this knowledge for optimal solutions within various applications.
Why Maintainability Should not be an Afterthought
Jerry Putt, Noria Corporation
Equipment will require maintenance, so why make it more difficult than necessary? Whether you employ run- to-failure or condition-based maintenance strategies, you should strive to make all tasks as maintenance friendly as possible. This session will explore first principles of maintainability as well as ways to convert many inspections into effective runtime tasks.
