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August 11, 2009 A Penton Media Publication Vol. V No. 15


CONTENTS
Maintenance Misalignment, Part Two

Maintenance Data Granularity

Electrical Troubleshooting Quiz

Failure-Mode Coding for Motors

NEC in the Facility

Safety


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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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    Maintenance
    Maintenance Misalignment, Part Two
    If your maintenance program is misaligned with your mission, resources, or priorities, how can you line it back up? Here’s a way to get started:
    • Access maintenance records for the past year.
    • Sort completed maintenance activities by labor cost (or time spent), greatest to least.
    • Plot the activities on a bar chart, in descending order of labor cost.
    Now you can clearly see which activities consume the most maintenance labor. By addressing those activities first, you maximize recovery of wasted resources.

    To read more on this story, visit EC&M's Web site.


    Maintenance Data Granularity
    A good CMMS is more than a system for processing work orders. It provides a variety of tools for analyzing maintenance data. The usefulness of those tools depends on the accuracy and granularity (depth of detail) of the data provided.

    To avoid guesswork and confusion due to granularity problems, structure your data in a logical hierarchy. For example, instead of listing "contact corrosion" and "lead corrosion," put the key term first so you have "corrosion, contact" and "corrosion, lead." This makes logical filtering and sorting possible. It also enables you to have drill-down and overviews in the same system.


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    Repair
    Electrical Troubleshooting Quiz
    A complex conveyor system threads its way through the plant. This system has a large number of 10-hp motors, and you replace one every few weeks. Your company's policy is not to send "throw away" motors out to your motor shop for a post-mortem.

    Today, yet another motor failed. You noticed a burnt smell. What's a compelling reason to send this motor out for a post-mortem despite the policy, and what should you look for while it's being examined?

    Visit EC&M's Web site to see the answer.


    Failure-Mode Coding for Motors
    How can you solve for recurring causes of motor failure? A key step is to know what those causes are. Toward that end, provide motor repair forms with motor-specific failure mode codes. Start the list with a few likely causes, and update after each motor post-mortem so your form matches your actual problems. The form should also include checkboxes for these observations:

    • Misalignment.
    • Burnt smell.
    • Water intrusion.
    …and these measurements:
    • Phase-to-case fault.
    • Phase-to-phase fault.
    • Open winding.

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    Operation
    NEC in the Facility
    As the problems of the economy have dragged on, most companies have stepped up cost-cutting. This is a good idea if done intelligently, but sometimes it’s not. The budgets for electrical projects and plant maintenance are favorite targets for the infamous "10% reduction" target issued without regard to operational realities. The results can be expensive, or even fatal, to the corporation.

    To read more on this story, visit EC&M's Web site.


    Safety
    Personal protective equipment (PPE) is the last line of defense between you and a hazard. Inadequate PPE or incorrect use of PPE can result in painful injuries or even death.

    General PPE (e.g., safety glasses) protects you from general hazards. Some PPE (e.g., canister respirators) protects you from specific hazards. Always assess the area and the work for the hazards that are likely to be present, then obtain the PPE designed for those hazards. Before using any PPE, inspect it to ensure it's serviceable. If it's wearable PPE, ensure it fits properly. If it's non-wearable (e.g., blanket), ensure it's installed and secured properly.

    As noted, PPE is a last line of defense. Reduce hazards and your exposure to them by following your facility's safety practices and applying NFPA 70 around electrical equipment.


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