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CONTENTS
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Midwinter Boosts to Summer Maintenance
Electrical Troubleshooting Quiz
Planning for Repairs
NEC at the Facility
Combating OSHA Fines
It's Time to Hit the Beach
Answer to Electrical Troubleshooting Quiz
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About This Newsletter
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This twice-a-month e-newsletter is brought to you from the
publisher of EC&M magazine. MRO Insider addresses topics such
as:
Working with management and supervision
National Electrical Code® on the production floor
Safety procedures and programs
Troubleshooting techniques
Equipment maintenance and testing tips
Managing motors and generators
Trends in training and education
Managing energy use
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The designations "National Electrical Code” and “NEC” refer to the
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Maintenance
Midwinter Boosts to Summer
Maintenance
It may seem counterintuitive, but winter provides many
opportunities to reduce summer maintenance costs and summer cooling
bills. Some pointers to consider include:
- Most facilities use less far electricity in the winter than they do
in the summer, because the summer cooling load is absent. Power quality
tends to improve, because the nonlinear compressor loads are also
absent. If you had power anomalies last summer, take baseline power
quality measurements now. Having this information during high demand
periods will shorten troubleshooting and facilitate system optimization
because you've isolated hot weather-related variables. Using the full
ability of a power analyzer will provide you with a robust data set. If
you don't have a power analyzer, this single use will probably justify
the purchase.
- Inspect electrical rooms and enclosures for winter animal nests.
Animals evicted from other sites may have moved to yours. If nests are
present, contact your local animal control office for instructions on
how to safely and humanely relocate the animals.
- Use infrared to look for air leakage around windows, doors, and
other openings. With the higher temperature differential that winter
provides between indoors and outdoors, these should stand out more
clearly than in summer.
- Cold weather reveals make-up air imbalances. Most systems today are
automated and adjust the air mixture per programmable parameters. Visit
various spaces at different times to see how well the system is
maintaining control. The correct solution may be hardware, not a
parameter change -- so investigate imbalances carefully before
deciding on a course of action.
- Plan ahead for spring and summer maintenance projects. Identify
training deficiencies while there is time to correct them, order
long-lead time parts, review maintenance procedures against maintenance
reports, and generally tune up your maintenance processes. If you're a
plant engineer, review lawn care contracts before spring demand
hits.
Be careful: winter testing can also work against you. For example, some
firms offer "winter rates" for HVAC maintenance during the slow winter
months. Some testing may severely damage some equipment. Check the
specs
on your HVAC equipment to determine the minimum recommended temperature
of operation. If, for example, a compressor operates below its minimum
operating temperature, the oil will not circulate -- and the unit
will
be irreversibly damaged. If it subsequently fails on the first hot day,
you may not be able to replace it until well into the cooling season.
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Repair
Electrical Troubleshooting
Quiz
Over the past several years, several 10-hp motors have
failed on conveyor systems throughout the plant. The problem is almost
always the same: bearing failure. The motors are sized correctly, and
there are no jarring loads on the conveyor. Operators report that the
motors seem to shake loose, even with the instruction in the PM
procedure to check the mounting hardware. What is the most likely
problem?
The answer to this question appears at the end of this
newsletter.
Planning for Repairs
Looking into next year, do you expect the number of
repairs to increase, decrease, or be about the same? More specifically,
do you expect to be doing the same repairs on the same equipment next
year as you did this year?
Here's a way to prevent "déjà vu all over again" for
repairs:
- Identify the three most common repairs done on each of your three
most repaired pieces of equipment.
- Contact the manufacturers of each piece of equipment, and discuss
these repairs with them. Ask them for suggestions on how to reduce or
eliminate these problems in the future.
That reduces the volume of repairs. To reduce the cost of
repairs (in terms of lost revenue), repeat this process for your three
most critical pieces of equipment.
Another important step in reducing repair repetition is to pay close
attention to the people doing the repairs:
- They often have insight. Ask them to share it. Sometimes, a
seemingly minor change in parts, materials, or procedure can eliminate
a
persistent problem.
- Their methods may be the problem. Have someone research the correct
way to perform a given repair, and then compare that to the method(s)
being used.
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Operation
NEC at the Facility
If you install a gang receptacle with a deep receptacle
box behind it, you can reduce installation costs by putting your
splices
for another switch in that box, right? Probably not. You can't use an
enclosure for a switch or overcurrent protective device as a junction
box that way unless conductors fill the wiring space at a maximum of
40%
-- and the splices fill the wiring space at a maximum of 75% (at any
cross-section) [312.8].
Combating OSHA Fines
One key to preventing OSHA fines is to know what OSHA
inspectors look for. Like any federal agency, OSHA operates on the
basis
of rules -- and paperwork that shows compliance with those rules. A
safety program that focuses on engaging managers in eliminating unsafe
acts in an informal manner will dramatically reduce the likelihood of
accidents. What it won't do is produce the necessary documentation
trail. This is why one popular program developed by a major chemical
company makes use of checklist cards (turned in on a regular schedule)
for the managers. If you aren't documenting your safety actions, those
actions will probably be invisible to OSHA inspectors.
Show & Events
It's Time to Hit the Beach
If it's your job to make sure all systems are "go," you
need to go to Electric West. This show and conference offers the right
information and product mix to meet all of your information needs. Do
you maintain and operate electrical systems in a facility? If so, you
have to make plans to attend the Electric West conference program next
year in Long Beach, Calif. Check
out this event's 40+ seminars in the areas of power quality,
safety,
Code changes, and industrial applications, and make plans to meet 200+
leading suppliers. Or register
now.
Quiz Answers
Answer to Electrical
Troubleshooting
Quiz
People who aren't trained in fastener application and
maintenance usually interpret "check the mounting hardware" as "turn
the
bolts tighter." This produces two results for motors:
- Bends the motor foot, throwing off the mounting geometry.
- Stretches the bolt beyond the length of maximum clamping power,
thus
reducing the applied force of the fastener.
To fix this problem, revise the PM procedure. It's inexpensive to mark
each nut/bolt connection with a marker fluid for the purpose, after
it's
tightened to the correct torque value when newly installed. Loctite is
one manufacturer of this product. The fluid leaves a visible line
across
the connection. If the fastener moves, the line breaks. Consider
installing vibration-monitoring equipment, so you get an alarm when
there's a problem rather needing to do repairs between PM
inspections.
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