|Maintenance tech tip
|Writing the Perfect PM
The first step
to developing the perfect PM is to develop a template.
This template should be built on a logical sequential
order. It must be
worded clearly and concisely and it should contain these points
and probably more.
A contact person for
the area of work. Communications
Each step needs to
have some form of a check off such as a ___ or o.
well documented such as “lock out/ tag out” procedures or
equipment specific safety precautions.
A listed of all needed
parts and special tools.
When using the word
check or inspect, be clear as to what needs to be looked at and if
needed what to do when found.
Example: Inspect shaft
for signs of wear such as cracks or discoloration.
If found note on inspection sheet.
Example: Check meter.
Meter should read between 25-40.
If out of range either way note on check sheet and
immediately inform shift supervisor.
Task sheets need to be
written for the specific skill level doing the work.
Task sheets need to be
written as if employees
are new to the facility.
Task should have a
specific crew size and hours.
When working on
multiple levels or equipment, a flow to the work should be laid
specifications are always needed when performing the task, they
need to be included.
If OEM manuals or
prints may be needed for reference, always give their locations
A sign off at the
bottom of the task sheet that shows it was completed should be
Periodically, give out
a task planning survey sheet when doing the task.
This feedback will be invaluable to the planner and gives
the workman say in design.
I often wondered how they loaded the Cole on that Norwegian
transporter. Quite an innovative engineering
Subject: Pump Failures
response to your request to help out the reader, Farouk, with his
question on pumps, here's the main causes we have identified for
these types of failures:
between the pump and the driver. We use a laser alignment
tool on all direct coupled pumps and ignore the OEMs maximum
permitted misalignment figures and aim to get the smallest
misalignment possible (well below the OEM recommendation)
or broken foundation bolts. If the frame's not held down
tight - you're going to get vibration.
mounting frames. In an effort to be competitive, OEMS make
the frame as light as possible. Often a few stiffening
ribs, or filling the frame with grout will help things along.
loads between the outlet piping and the pump. Pipe-work
misalignment can put a load onto the pump, leading to vibration.
Always use a flexible joint between the pump and the pipe-work.
high temp is often caused by over-greasing. We have had
several cases where a bearing temp goes high so the first
response is to add more grease. If it's not leaking out,
you don't need to put more in.
main thing to remember in these cases is the laws of physics.
Vibration is a measure of acceleration and F=Ma.
Therefore, start looking for the force that is causing the
Hope this is helpful.
Callide Power Station
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RE: Have a Safe New Year
With the first issue of our newsletter for this year we are pleased
to deliver valuable information new to the industry. As you share this information with
your associates, be sure and let them know www.feedforward.com.au was the
first to release it!
Happy New Years, and welcome to January's issue of our Feed Forward Newsletter! My name
is Don Fitchett, the author of "The Maintenance War Newsletter". This first area of the
newsletter is for introductions and commentary. I would like to start by
wishing you all a productive and safe new year.
If a friend has given you this copy of the newsletter,
you can find an online version on our website www.feedforward.com.au
Every month we add new book titles for you to download, free
articles and other resources.
In the spirit of the common greeting used world wide; 'Have a safe new
year', we present to you this month a new Safety book before it hits the
book stands and a new concept that is sure to revolutionize the
reliability industry. I hope this month's newsletter helps you fulfill a
new year's resolution of constant improvement in both safety and
Mike Sondalini has favored us by letting Feed Forward Publications be
the first to release his new article and concept. With his article 'The
One Absolutely Critical Point RCM, FMEA and the like All Miss!',
Mike is introducing the next evolution in reliability. After 300 years, it
is time for Engineering Driven Reliability (EDR)!
Last month we promised you Mike Sondalini's totally new presentation of
and reliability combine to deliver availability. This is a collaborative
article by Mike and retired vibration analysis expert Max Wishaw.
Max uses charts to keep it simple while delivering a clear picture of the
We are also thankful to author Randy DeVaul
for letting us publish his new book, 'Performance
Safety: Lessons For Life' and for the great article 'Total
Performance Safety – Real World Safety in the Real World' he donated
for our readers. Randy's contributions will surely lead to a safer new
year for us all.
this month, watch our website for a new revision to Mike Sondalini's Ebook 'Belt
Bucket Elevator Design, Use and Care' It
been in the top 5 seller list since it's release. The revised Ebook is
titled 'Belt Bucket Elevator Design, Use and Care
- Second Edition'.
Second Edition gives greater detail on bearing selection, shaft dust
sealing, belt tensioning, dust extraction, belt and bucket selection,
hazardous applications and a lot more on proper use and care. Mike has
indicated there is more focus on a buyer's perspective to help
in selecting equipment for purchase.
Safety - What is it?
Safety re-focuses attention back to the basic fundamentals. It is defined
as an on-going review of processes, procedures, and individual/team
practices through three basic methods: workplace examinations,
observation, and task analysis. It provides a pro-active, continuous
improvement environment to encourage safe production at all levels.
Safety recognizes individual and team performance in pro-active (not
reactive) injury prevention techniques that will totally prevent, or at
least, reduce exposures to hazards. It allows employees at every level to
achieve optimum performance by:
and correcting any unsafe condition or practice – individually
and as a team.
more efficient, safer ways to perform a task.
processes to adjust for newly-identified hazards.
Safe Operating Instructions to ensure consistent and repeated
safe instruction and performance of the task(s)
Safety involves all aspects of a person and company’s performance, so
defining an unsafe condition and unsafe act are based on performance
Condition: exists if an individual does not have either knowledge or
control over existing circumstances that may be unsafe, that would
otherwise suggest he would not perform the action.
Act: an action taken by an individual who has both knowledge and control
of an existing unsafe condition or action, but chooses to perform the
action or ignore the condition.
above definitions account for behaviors, corporate culture, and
employee that has not been trained properly may not know how to do the
task properly, resulting in an unsafe condition. He is not choosing to do
it with risk, so it is not an unsafe action being performed. An employee
that knows how to perform the task but circumstances take the control away
would also be an unsafe condition. For example, while welding, an employee
must bend at the waist to reach the work area. There is no mechanism
available to allow him to reach it from a different angle. As a result,
the employee experiences back pain while performing his duties. He had no
control over the location of the work and was unable to modify the duty to
protect his back. This is an unsafe condition.
employee knows how to properly perform a task and has been trained
specifically in this task, yet he insists on modifying the procedure to
“save time.” He has full control in the decision to perform the task
and has all the appropriate tools and equipment to complete the task
safely. An example is choosing not to wear leathers to weld and, as a
result, the employee catches his clothing on fire. This is clearly an
unsafe act. The process is clear, the procedure is clear, the practice
(behavior) is at-risk.
Safety, then, takes into account the practices (employee choices), the
procedures (identified way the task should be performed, if identified
correctly), and the overall process (employee training, employee
expectations established through corporate culture and management, etc).
month's management section written by Randy DeVaul
author of 'Performance
Safety: Lessons For Life'
This month's newsletter is sponsored by the
Institute for International Research in Australia. www.iir.com.au
here for a copy of the brochure for the Seminar/Workshop on
and Managing Shutdowns and Turnarounds"
- 30 March 2004
Venue: Novotel, Brisbane
Have a Safe New Year:
How about 254 Safety related free
power point downloads and over 140,000
msds files as just a couple of the many great resources you can find
Another great source while improving your plant safety is the OSHWEB, a
of safety related internet resources.
For Reference: The
Office of Hazardous Materials Safety - http://hazmat.dot.gov/
Within the United States Department of Transportation's
Research and Special Programs Administration, and responsible for
coordinating a national safety program for the transportation of hazardous
materials by air, rail, highway and water.
Well this month's bit of entertainment is a question that the answer may make you
laugh, you may think it is cool, or you may just get up set. :>) I have
quizzed my friends for more years than I can remember and no
one has figured it out. So I will give you a clue, it is a play on words.
(The first one to get it right will receive a prize!)
You are placed in a room (a cube with 6
sides), made of steel. There are no doors or windows,
all that is in the room with you is a mirror and a table. How do you get
Next month we will give you the
Best regards and thanks for being a subscriber to this
Feed Forward Publications
Tel : (573) 547-5630
www.feedforward.com.au teaches your maintenance crew engineering and asset
care knowledge so that they can solve more problems, become more
knowledgeable, make better decisions and your plant runs more reliably!
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