Come along on our PdM journey that resulted in the partnership with Timken Industry Services, Ivara, and Gallatin Steel. When we implemented Ivara EAM in 2001, we knew we needed to assess our PdM program. Our first task was to do a criticality assessment. Next, we did our PdM needs assessment. All though, we had been doing vibration and thermography since 1995, this gave us a clear direction to go. We will talk about our vendor selection process and why we made our choice. In addition we will cover our interface with Ivara, and how we track our finds and follow up on issues using EXP. One key factor of any PdM program is the follow up. Due to Timken's commitment to the success of our program, we have seen a decrease in our emergency work orders and an increase in reliability of our equipment.

Construction of our Compact Strip Production (CSP) facility began in 1993. We began our start-up operations in the second quarter of 1995. Gallatin Steel Company (GSC) is a joint venture between ArcelorMittal Dofasco and Gerdau Ameristeel. We have achieved the ISO 9001, ISO 17025, and the ISO/TS 16949 Certification. Gallatin Steel currently has 430 employees and has received the Best places to work in Kentucky award the last 3 years. We currently produce more than 1.5 million tons of hot band coils on an annual basis. Our steel manufacturing facility is located along the banks of the Ohio River on U.S. 42 in Gallatin County, Kentucky, USA.

Winner (Best Ultrasound Program) Uptime Magazine PdM Program of the Year 2007

This paper and presentation will document a five-step process Hamilton Sundstrand used to transition from reactive maintenance to a condition-based maintenance organization. We will demonstrate how our team applies PdM technologies as a key instrument in that “step change.”

The process Hamilton used mirrors Six Sigma Methodology (the DIMAC model). By identifying an implementing five key steps Hamilton Sundstrand was able to systematically start the conversion from the traditional, reactive organization to a proactive organization. These fairly simple steps include the prioritization of critical equipment and systems, establishing technologies to be used and the frequencies that data will be collected, analyzing that data to identify pre-catastrophic failures, addressing all anomalies and finally controlling the process.

As a proactive organization can now take advantage of additional new found efficiencies to even further improve our organization’s performance. From our perspective, that of a close customer-vendor relationship, our paper and presentation will answer some the questions regarding “how to” implement a condition-based monitoring program.

It has been estimated that the exclusion of system contamination costs about one-tenth what it would cost to remove the contamination once it has entered our system. Therefore, we must evaluate the options associated with the exclusion of contamination vs. the removal. Advances in proactive maintenance have produced numerous products that will prevent the ingression of contamination. We need to look at the proactive options for maintaining lubricant and mechanical reliability and for sealing our systems from their surrounding environments.

Solutions & Innovations Session A
Diagnostic Aid Provided by Autocorrelation by James C Robinson and Allen Collette, Emerson

In this paper, the focus is placed on the analysis of the output of an accelerometer placed on rotating machinery (generally placed on the bearing housing) in an industrial environment. The emphasis will be on the diagnostic aid provided by a not widely used function identified as the Autocorrelation Coefficient Function. The autocorrelation coefficient data are computed from the same digital time waveform from which the widely used spectral data are computed from. It will be demonstrated through case studies the autocorrelation coefficient data are very complimentary to the spectral data for diagnosis of vibration data.

The computation of the Autocorrelation Coefficient Function data will be briefly introduced. This will be followed by strengths (and weakness) of the autocorrelation coefficient data relative to the spectral data employing selected field data. Case studies are then presented where the diagnostic aid provided by the autocorrelation coefficient data was critical to the task of identifying the source (cause) of the observed vibration data. The case studies will include situations where the spectral data identified probable periodic activity but the autocorrelation coefficient clearly showed no periodic activity was present thereby avoiding possible erroneous conclusions.

The Autocorrelation Coefficient Function is relatively easy to compute on the PC computers normally used for vibration based condition monitoring. It provides a powerful tool for aiding in the analysis of vibration data and can assist in coming to false conclusions.

The measurement of condition of bearings rotating at speeds below 60rpm using vibration is fraught with difficulty.

This presentation uses a portable ultrasound system as an "intelligent sensor" in association with a normal vibration data collector to overcome this problem.

The presentation includes results of measurements taken on a group of rotary crushing machines where this combined approach reduced the measurement time from 21 minutes per measurement to under 2 minutes per reading.

The San Onofre Nuclear Generating Station (SONGS) is located south of San Clemente, California in northern San Diego County. The plant contains three nuclear reactors, Units 1, 2, and 3. Units 2 and 3 are currently in use and are capable of producing enough power to serve the needs of 2.75 million households (2,254 megawatts).

The oil analysis program is committed to increasing the plants overall reliability by applying industry’s best practices coupled with aggressive continuous improvement plans and metrics that show program growth and effectiveness. During recent years, the SONGS oil program has expanded to a scope to 418 individual component locations, with the majority of these locations having oil sample valves installed.

Installation of the sample valves has resulted in on-line oil sampling by plant operators and has eliminated several hundred PM tasks that were previously used to collect these samples. The oil analysis program owner has aggressively implemented industry’s best practices and the program measures itself against a 11 key element metric system on a quarterly basis. The metrics focus on areas of contamination control, storage and handling, lubricant analysis and program management.

There exists a critical need in the asset maintenance and reliability industries to empower engineers and field personnel to determine oil quality on demand and provide complementary oil condition information that has been traditionally obtained from oil analysis labs. The current methodology of testing in off-site labs is non-optimal and costly due to the logistical challenges of shipping samples and the time delay in getting information back to personnel to be able to make quick and informed decisions.

Measuring the viscosity, dielectric and conductivity of oil is a rapid method of determining oil condition, and is considered an important parameter in assessing equipment readiness. A real-time on-line bolt-on threaded fluid condition sensors can compliment IR spectroscopy and other bulk property sensors. They can provide instantaneous on-line viscosity, water contamination, fuel dilution and temperature data, have no moving parts with an extremely wide operating range and offer universal plug-n-play connectivity for integration with and into other handheld products.

The SenGenuity Fluid Condition Sensor  measures directly and individually the acoustic viscosity (AV), dielectric and conductivity values of oil. Highlighted in this article are methods to establish correlation between acoustic viscosity and dynamic viscosity and to highlight customer success stories demonstrating the value of the on-line sensor with actual case studies.

Vectron’s highly sensitive bolt-on FCS in an online configuration provides the benefits of fast result reporting, simple installation and advantageous cost/benefit relation. The FCS™ measures viscous damping of a surface shear wave on a quartz crystal to obtain the viscosity-density product of the sample, while at the same time using a common electrode design to measure dielectric and conductivity. The sensor offers solid state reliability, real-time response time and is immune to flow conditions and vibration while designed for the challenging process control environments and for OEM applications.

Would you like to learn what can be gained by measuring vibration from rotating machinery? Would you like to understand the spectrum, time waveform and phase measurements? And would you like to see proof that vibration measurements can be used to detect faults and diagnose the nature and severity of the fault condition? If so, then you should attend this very dynamic and visual presentation.

Utilizing the Mobius Institute iTeachVibration simulators and animations, you will see first-hand how the vibration and phase measurements are collected and transformed into the waveform and spectrum. You will see how the frequencies generated by the machine relate to the rotating components (bearings, gears, fan blades, etc.) and provide a direct indication of the health of the machine. And you will learn about the limitations of the standard "overall level" measurement, and the benefits of high frequency bearing measurements. By the end of the presentation you will feel confident that vibration monitoring can provide an early warning of a wide range of fault conditions in rotating machinery; information that can help you to reduce downtime and better plan your maintenance activities.

Electric motors, whether AC or DC, will vary considerably in construction, operation, and performance. All share a distinction, though, in usually rating high on reliability incident reports. The "bad news" is that this was the case at an SKF plant in Hanover, PA. The "good news" is that solutions were found, valuable lessons were learned and others in industry can now use the tools and expertise deployed to help keep electric motors performing with minimal problems and downtime.

A catalyst to expedite a solution came with an internal SKF program (the "PRE-FORM Project") launched with the goal to establish ever-higher quality and precision standards for all SKF facilities worldwide. In Hanover, the program, in part, required that overall vibration levels of the grinding machines would have to be reduced and that the performance of the electric motors would have to be enhanced to help contribute to improved plant output and quality.

In Hanover, electric motor reliability at the grinding machines is no longer an issue and measurable savings have been realized. The plant has reduced the total cost of motor maintenance by almost 40 percent and technicians now can spend more time implementing focused procedures instead of puzzling over problems.

Proper bearing lubrication is critical to bearing life because 50 percent of all bearing failures can be attributed to inadequate lubrication. "The Fundamentals of Bearing Lubrication" presentation gives a brief introduction to the various bearing types and their lubrication requirements as well as the mechanism for generating a protective lube film. Types of lubricants, such as oil and grease, are discussed in depth along with the bearing damage modes associated with inadequate lubrication. Some grease selection guidelines will also be presented.

Global competition, coupled with energy prices that are at an all time high, are forcing many companies again to review and search for a “proven” method of reducing their overall maintenance costs while increasing the reliability of their aging equipment. Despite the continuous preaching of the benefits of implementing an effective lubrication program, many organizations still lack the formal direction and understanding required. This paper will provide a proven methodology and direction to obtain the benefits of a Well-Engineered Lubrication Program.

Rotating equipment in production facilities offers optimal performance and reliability when properly installed, maintained, and operated. Condition monitoring devices and systems are utilized to keep tabs on the operational performance of key production equipment. All types of tools and technologies exist today in the predictive maintenance field to allow monitoring and assessment of such equipment. In many cases, a structured portable, walk-around program will suffice. In other situations, where equipment is hard to reach, inaccessible, or located in a dangerous or hazardous area, a permanent installation of sensors and surveillance hardware is necessary. Key objectives for such a maintenance program are to minimize failures, reduce downtime, and to reduce costs.

Recent advances in electronics technology have allowed online predictive maintenance systems to be more affordable, reliable, flexible, and modular. These systems have proven to be quite effective in providing early warnings and pinpointing root causes for machinery faults and failures. Online systems can measure and record many process parameters, allowing the user to trend and trigger on alarms so that machine performance and health can be monitored along with vibration-related faults.

This paper will focus on the ideal application of continuous surveillance systems, the economies of scale, and the distinct advantages relative to implementing a traditional portable, walk-around program.

It has been over twenty years since the Predictive Maintenance Industry has had narrow band alarming and only Technical Associates of Charlotte has written any major work on the subject.

Most vibration training classes go over what are narrow band alarms and the advantages of using them. The purpose of this paper is to inform the reader on how to make narrow band alarms for data screening and trending analysis.

The NFPA 70E regulations define a series of boundaries related to electrical safety when working on energized equipment.

Arc flash is a serious hazard that can be devastating to those exposed to it. It can also cause lengthy downtime to repair or replace severely damaged equipment. The requirements of NFPA 70E help plant and facility managers to reduce the probability of an arc flash event and its effects.

The vast majority of arc flash incidents occur when there is a change of state within the panel (opening the panel doors, removing covers, etc) or through operator error (dropping tools, touching live components, etc).

This short course explains the basics of NFPA 70E and some strategies to ensure safety and minimize risk.

Condition Based vs. Time Based Lubrication of Bearings

Bearings lubricated on a time based schedule are more prone to premature failure than bearings that follow a condition based schedule. In a time-based scenario lubricant is rarely added at the exact time it is needed; allowing the bearing to run "dry" for extended time frames. When the bearing is finally greased the amount of lubrication can be too little or too much. In either case the implications for bearing life are negative.

A condition based schedule involves frequently monitoring the bearing to establish normal baseline friction levels. As the job of lubricant is to reduce friction, it stands to reason that increased baseline readings would indicate a need for re-lubrication. Monitoring friction levels while lubricating serves as a guide to prevent over lubrication.

A simple and common approach to monitoring and setting baseline friction levels is with an ultrasonic data collector. These portable instruments use high frequency piezoelectric sensors to detect, measure, and trend ultrasonic signals from rotating equipment. Friction from the bearing excites the sensor which in turn produces a micro volt charge which is accurately measured and referenced to a decibel log scale. This data is displayed onscreen and stored to the internal data collector. It can then be transferred to PC where for further analysis. As a rule any bearing with a measured ultrasound value 8-10 dBµV over its baseline should be greased using the acoustic lube method.

The use of high frequency compression wave analysis for bearing condition evaluation was pioneered by SPM Instrument nearly 35 years ago. It remains today as the practical front line method for identifying lubrication issues and bearing damage for ball and roller bearings. This workshop will provide the technical theories and practices that make up the methodology used today. The relationship between the shock transient and the traditional vibration sine wave will be examined and how this makes shock pulse monitoring more accurate for a wider range of rpm's. Case studies will be presented along with a visual real-time test of bearings under different operating conditions.

In an ever-changing global marketplace it is more necessary than ever for PdM to be escalated to another level. Annual infrared inspections sometimes result in findings of issues that need immediate action. Taking advantage of more advanced methods of communication provides the ability to cross time and space. WiFi, Smartphones, and Bluetooth put the ability to respond to emergency issues into the reach of regular maintenance personnel as well as the PdM technician. The introduction of SD Card based nonproprietary image infrared cameras and more widespread use of PDAs and Smartphones by maintenance personnel has opened doors to increase the awareness of issues that in the past received only "lip service" emergency priority. Maintenance personnel can now transmit digital proof of serious issues to management and receive immediate authorization for a shutdown repair prior to failure. More widespread use of these small PDAs and Smartphones also allows for users of older cameras to inexpensively upgrade to digital to perform immediate documentation of the issues allowing for faster report completion and return to the "end customer."

Join Matt Willems and Nick Bohonik of Johns Manville to learn about a 10 Piece “puzzle” that JM assembled into Uptime Magazine’s Award winning 2006 Best Infrared Program of the Year.

Synopsis: Lubricated equipment at POSCO is massive in quantity and critical to production. In this presentation, I am going to show you what POSCO has been doing for the improvement of lubrication systems and what POSCO will do in  the future.

This presentation will be focused on the following subjects.

-. Lubrication control at POSCO(Standardizations for new oil & used oil, and Process of oil analyzing for critical systems)

-. Practical examples of lubricated machine failure

-. Preventing from failure before shut down using FFA or Grease FE

Detector

-. Developments & applications of new technologies

. Introduction to On-Line Wear Monitoring system (OMD)

. Filtration system for high viscosity fluid

-. Application of oil changing for better performance

. Changing hydraulic oil from EP mineral to Zn-FREE in cold rolling mill

. Synthetic gear oil application to Furnace Tilting Equipment

. Application of Oil-Air System in continuous casting machine l, etc

All the data presented here are based on practical applications in Kwangyang Works, POSCO, in Korea.

The Lynchburg District VDOT fleet consists of approximately 800 plus items with an overall value of approximately 35 to 38 million dollars. We maintain seven full service repair facilities with 29 Techs on staff and six out of seven facilities hold an ASE Blue Seal certified status.

In 1995 we began our CMMS driven PM Program. Prior to that we were utilizing what I would call a "scheduled maintenance program" and in some case a "failure maintenance program". Each of these generated some benefits; and, yes, even "failure maintenance" can be somewhat advantageous under the right circumstances. The problem we were facing was that although our E.Q. was performing better and our uptime was improved our cost continued to increase faster than our E.Q. performance did.

In 2003, we re-evaluated and changed our strategy and began to focus on five levels of maintenance. It became apparent that the dynamics of our maintenance program include parts of all five levels; and if we hoped to build a strong program we would need to break them down into the five levels in order to communicate to our personnel the rationale and benefits of this approach. Our program is presently occupying levels four and five and steadily evolving. It is my opinion that once your program has mastered all five levels you will then have reached the pinnacle, a RCM Program. Since we have changed our focus and strategy, our program results have been excellent and as we continue to learn, evolve and improve we expect ongoing positive results Stevens, Carlton D., C.E.M. (Carl).

Case study on continuous vibration monitoring on a fan that is using compressed air to keep fan bearings cool. Fan is a direct drive 400hp 1800rpm controlled by a Variable Frequency Drive (VFD). The machine is 12-18 months old with vibration levels above 1.0 in/sec and customer has replaced fan bearings four times. Bearing replacement is a symptom is this case and the root cause is flaw in machine design/installation.

One of the components of the development of a successful motor management program is the use of Electrical Motor Diagnostic (EMD) technologies for condition-based assessments, troubleshooting, and commissioning of new and repaired electric motors. In this presentation, the authors will discuss the impact of the use of EMD on automotive plants and will present several cases related to the identification of issues and resolution through the use of EMD in commissioning. The case studies include the identification of poor practices by repair vendors to improvements in maintenance best practices on critical equipment.