The "What" and "Where" of PM consists of what equipment is to be inspected and lubricated and to what extent and detail the work is to be performed. Typically detailed PM and PDM procedures are written for all production equipment to insure that all machine components are inspected and lubed for maximum sustained operation. This process should also be applied to other plant equipment systems, such as machines that supply the plant utilities including air compressors, air dryers, boilers, electrical sub-stations, motor control centers, and wastewater treatment. Plant safety systems also should be included, including natural and propane gas systems, tanks, fire alarms and suppression systems, emergency lighting, overhead cranes and hoists, and ceiling mounted items such as lights, fans, and piping. Many plants also choose to include PM work on HVAC systems, overhead door and dock plates, forklifts, company vehicles, truck fleets, roof leak detection, air emissions and other systems usually not considered until there is a problem.

The detail and extent of the PM and PDM work varies with the type of equipment involved. The written PM procedure is the document that tell workers what needs to be done. This document needs to contain all of the tasks that will provide the most thorough inspections and lubrications of machines in planned down time, without exceeding the point of diminishing ROI. Generally, the PM inspections of most machines are one of two types. The first is for any thing that moves or causes some other machine part to move. This needs to be inspected for damage, wear, loose and missing fasteners, etc., and proper lubrications performed. The second is the inspection of static, non-moving machine components such as wiring, plumbing lines and hoses, structural support members, etc., for damage, cracked welds, loose and missing fasteners, etc. These procedures may be lengthy or simple, depending on the type of machines involved. The main concern is that the person writing the procedures is very experienced in plant maintenance and plant engineering. This person must understand and be experienced in all phases of static and dynamic machine principals and actual machine degradation analysis.

"When" PM should be performed depends on several factors. Some machines are simple in design and function and some are not. Typically, there are items to be inspected and lubricated on a daily basis. Other inspections and lubes are progressively more detailed and regularly performed on a bi-weekly, monthly, quarterly, semi-annual and/or annual basis, depending on what is required.

In addition to the machine design and basic function, several other factors help in determining the best time interval between PM tasks. One is the amount of time the machine runs between regularly scheduled shutdowns and/or how much time is available for PM. Does the machine run 24 hours per day, seven days per week, or eight hours per day five days per week? Another factor is the environment in which the machine runs. Is it humid and damp, or extremely hot and dry? Does the machine receive shock loads or run with moderate to high vibration levels? Is the machine subject to chemical spillage or leakage, ultra violet light, etc? Good operating and cleaning practices, or the lack of them, have a significant impact on PM scheduling. In addition, planned shutdowns for plant expansions, machine rebuilds, inventories, vacations, etc., also dictate when some of the more involved PM work can be accomplished.

Most of the above information relates to Preventive Maintenance procedures that are completed on machines while shut down. There are other tasks that are considered Predictive Maintenance (PDM) practices. One of these, usually done while the equipment is shut down, is oil sampling and analysis. Oil samples are taken and sent out to laboratories that specializing in analyzing industrial oils. The cost is relatively inexpensive and provides much valuable information. This process identifies the lubricating ability of the oil; its stability; contents of water, wear metal particles, and dirt; among other aspects.

Another extremely important PDM procedure is vibration analysis. Using a portable vibration analyzer, readings are taken from many points on machines. These readings are direct and extremely accurate measurements of the vibration amounts and frequencies produced by the moving parts of the machine. These vibration amounts and frequencies are used to tell if any parts need replacing or adjustment, and exactly what internal parts are causing problems. Bad bearings, excessively worn gears, and poor coupling alignment can cause excessive vibration, weakened mounting fasteners and many other mechanical problems. Vibration analysis also can tell you if pumps have loose impellers, air cavitation, faulty valves, or mounting problems. In addition, it reveals trending information. When vibration readings are taken, they provide a base number to use as a gauge to determine if and how much internal machine changes are taking place between inspections. This is the very best tool for detecting the correct health of machines and for trending the internal activities inside motors, gearboxes, pumps, large fans, compressors, and many other machine components. There is no better way to detect machine problems before they cause an unplanned shutdown due to a component failure. What's more, the fact that vibration analysis is done while the machines are running in their production modes allows the testing to be done at any time and is especially important for any plant that runs 24 hours per day, seven days per week.

There are many aspects of maintenance and other plant functions that have an effect on the number of machine breakdowns and the length of downtime. Some of these considerations are not normally associated with the term Preventive Maintenance, but nonetheless contribute to equipment failure. Therefore, they should be considered as a part of comprehensive approach to Preventive & Predictive Maintenance.

		Proper start-up protocols. Start-up operations; changeover and set-up; and shutdown procedures should be carefully planned and consistently implemented on all machines.
		Procedures lists for unplanned shutdowns. Outline what is to be done when an unplanned power outage occurs and what to do before the power comes back on.
		Emergency management plans for floods, fire, etc.
		Machine component rebuild programs to insure quality and consistency.
		Machine cleaning practices and procedures.
		Available informational equipment manuals for maintenance personnel.
		Solid troubleshooting skills by all maintenance personnel

The above information provides an outline of a comprehensive PM and PDM system. This approach is unassuming and leaves little, if nothing, to chance. While there are many variables to take into consideration, if properly designed, instituted and operated, the PM and PDM system will help to ensure dependable and predictable performance from all serviced equipment, machines, and related processes.

###

<<< back to Page 1

DPA . . .   Articles  |  Case Studies  |  News Releases