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Tuesday, August 30, 2016

THE BELLOW ACTUATED FLOW METER

The bellow actuated flow meter of consist of the constant high pressure and,low pressure chamber that are seperated with liquids and they are classified as filled below assembly.The left hand assembly consist of calibrated range assembly whose function in conjunction with bellows movement is used to measure pressure drop across primary elements. A connecting rod is connected to the left hand of pressure bellow and extend over to the right side of high pressure bellow, at which point there is an interval called spring. This connecting rod has the upper end of the triangular shaped torque arm attached to it by a cable assembly which is always in tension. The lower end of the torque arm is connected to a torque tube.Any horizontal movement of the connecting rod is therefore converted to a rotary motion of the torque. This motion is brought from the meter body unto the instrument case as a shaft rotation and used to actuate the pen linkage. The angular rotation is approximately 8o between the flow and maximum flow,Most bellow flowmeters meters are of the same general design The bellows are hydraulically formed: those of other make are of a welded construction. The internal parts of all are available, including the bellow made of type 316 stainless steel to provide maximum resistance to corrosion..There are various types of liquid filled  that are used by a different manufacturer which covers the operating temperature  - 5717 to 232 oC The manufacturer should be consulted as regards the special available oxygen intake measurement and includes lower and higher temperature of the secondary elements and the two complete systems.
A wide range of spring is available for measuring the pressure drop across the primary element for flow measurement . In addition, to terms of meters per minutes per second are used for measuring pressure drop across process vessels. bellow activated flow meters are also available for operating pressure up to  a maximum of 5000 psig. It is imperative therefore to operate the instrumentation of the machines to form operating element of the designs.

Friday, August 26, 2016

FLOW METERS

Mechanical flow meters are classified as rate meter because they measure and record or locates the rate of flow when measuring liquid or gases, the fluid are in direct contact with the actuating elements. when steam is measured, it condenses to water in the connecting pipe at atmospheric temperature  and is in contact with the actuating elements. the rate of flow is determined by measuring the drop in pressure of the fluid flowing through a restriction in the flow line. The restriction is shown in the primary elements. The flow meter has several designed of secondary actuating elements which are available and are in used in the industries. A early design is a mercury manometer , with flow resting on the surface of the mercury  manometer , with the flow resting on the surface in one leg .of the manometer .T he flow condition changes as flow varies and by a linkage mechanism. The pen or pointer is moved to correspond with the new rate of flow.for several reasons, such lower cost and easier installation and maintenance the use of  mercury less meters is  increasing rapidly, There were two general types ,i.e  (i) differential meter for measuring  pressure drop and its motion, (ii) the other type measures the pressure drop with a capsular assembly and transmit a standard of about 3 to 5 psig pneumatic signal. Most manufacturer published an accuracy of plus minus 0.5 percent for full scale displacement, for bellow meters. If an installation require better accuracy, it could be obtained by recalibration.
The general published for pneumatic transmitter is plus minus 0.5 percent for full scale displacement. Both types could be operated up to temperature  of 232 degree centigrade of the fluid in meter body.

Thursday, August 25, 2016

RECORDING INSTRUMENT.

Recording Instrument: A  relatively small numbers of recorders are used to record only the value of the process variables, a large number of these records flow with the total amount indicated by a mechanism.The majority of the recording instrument ae used for automatic control application, for this application,254(mm) to 304.8(mm) charts are the most desirable because of greater accuracy in reading and positioning the set point and a better opportunity of observing process trends. Recorder are available with one ,two, three, and four pens, Ink of different colours could be used and by using an eccentric scale which follow the time line of the chart and pointer on the pen arm .It is possible to have a combined recording and indication instrument. The use of a printer has been in used for so long that they are recently available with literally thousands of calibrations including those for a single variable and others multiple segments for two or more variables. The standard chart speed is the 24hrs revolution ,but many other speed and the required drive mechanism available. The drive mechanism may be electric, hand wound springs drive or pneumatically operated.

Monday, August 22, 2016

MECHAN-TRONICS VARIABLES

Mechanical instruments provides an accurate and economical means of measuring the status of nearly all process system. The instrument that measure all critical performance of process system are essential for all predictive and plant improvement programs. The information derived from process are used in-conjunction with vibration monitor,parameter infrared, interrogator to monitor predictive maintenance instrument, and other devices.  Mechantronics provide means for maintenance experts to liaise effectively  in any technical challenge and the method to enhance appropriate troubleshooting. and optimize the process. And the instrumentation aspect is divided into two variables i)Monitoring and Control..
 Process Monitoring: Mechanical instrument are mostly used to measure, record and trend variation in process parameters, such as pressure, low or temperature. In most cases the instrument convert mechanical displacement or movement of its sensor into corresponding proportional movement of a pen or gauge. These instrument generally transfer actual value of the measured parameter by means of a linkage mechanism,to a graph or displacement that is a part of the unit.
Process Control: The principle of the instruments are identical to those for the purposes of monitoring.In this instance, the instrument will translate the actual mechanical displacement into a proportional output, either pneumatic or electrical, that is used by the system control logic to adjust the process parameters.
Most process variable could be measured with mechanical instruments and may include the following:i. flow, ii. pressure iii. temperature iv.level and v. positions.The limitation are few, e.g pressure in micron range , temperature above 537.8 oC, and analysis of fluids.New designs and  materials for actuating element provides acceptable accuracy and sensitivity that are suitable for most applications These factors in addition to ruggedness include low cost and ease of maintenance,have resulted in an increasing use of mechanical instrument.for both monitoring and control of process system.In the industry they are classified by case size,type of recorders or indicators and form of charts or scales,In addition to the record or indication for the process variable instrumentation could provide automatic control integration of flow and adjustable alarm or signals for abnormal operating conditions.
Recording Instrument:A relatively small number of recorders are used to record only the value of the process variable,  A large number of flow with the total amount indicated by a mechanism.The majority of the measuring instrument are used for automatic control application.For this applications, 254 (mm) to 308.4 (mm) charts are the most desirable because of greater accuracy in reading and positioning the set point and a better opportunity of observing process trends .  Ink of different colors could be used and by using eccentric scale which follow the time line of the chart,and a pointer on the pen arm. It is possible to have a combined recording and indicating instrument. The use of  printer has been in used , for  so long that, they are recently available with literally thousands of calibration,including those for a single variable and others having multiple segment for two or more variable. The standard hour chart speed is the 24 hours revolution but many other speed and the require mechanism are available. The drive mechanism may be electric, hand worn spring drive or pneumatic operated.

Saturday, August 20, 2016

MAINTENANCE STORE AND INVENTORY CONTROL MANAGEMENT

There are various factors which affects the department ability to control cost. Among these are the age and the condition of the equipment, the skill of the labour force;the amount and the quality of information available to make decision, The size and the value of the store inventory to mention but a few.The inventory is a costly segment of the maintenance department budget, that until recently has not  much attention. In most company any reference to inventory usually implies production, work in progress or finished goods inventory, all of these are recognized as an asset in the general ledger. As an item on the general balance sheet they are continuously scrutinized and managed. Maintenance inventory on the other hand is less dynamic and often tend to be material shelved  to insurance purposes.Typically the maintenance  inventory when purchased is recorded as an expense and rarely shows up as a financial report this occurs despite the fact that its values in some larger plant could be several million dollars, (Ann,1995). In order to manage this inventory effectively, it is necessary to know its content and values.It is equally important to plan department actively similar to the way the production manager anticipate a production schedule. In such condition parts and supply are available when needed and not sitting for months even years before hands.In addition timing is critical when preparing production equipment in order to meet the goal of maximum availability. The maintenance planning system could be a microcosm of the overall business. these should be equivalent to order entry, production and bills. At the same time history records production improvement and cost  reduction programs should be recurring.The cornerstone of any maintenance planning is the work order.It serves as historical records and includes material cost and labour expense.Too often in some country history the work order,upon completion, is discarded or filed and never seen again ,thereby housing valuable information.More importantly the completion of a work order represent accumulated history of a piece of equipment,By analyzing these data, it is possible to anticipate repair practice preventive maintenance and avoid costly lost production potential poor quality.In addition with the many of the new technologies available, equipment can be diagnosed and until failure can be predicated.

Friday, August 19, 2016

MAINTENANCE PLANNING

Material and Parts Received: As the material and parts are received , they are  changed to work order , but when all the parts are received then the work order status is changed  from pending materials and parts in the backlog files.
All materials, parts and tools  are tagged to identify the work location and supervisor that would be responsible for the work, would  planned the work order accordingly. The planned work order status is changed to the appropriate ready to run category and it is placed into the back log file.
The work order is plotted from the backlog file with the  weekly schedule that be will handled by the work Supervisor..Effective planning requires observing planned job progress to eliminate potential delays or the problems that may arise.The planner should occasionally observe planned work in progress with the intention of improving his pre planning expertise.
During the follow - up process,the planner may address problem areas which are common to planning functions.These areas are:
Ensure that the communication is clear and adequate for all personnel involved on the job.
Ensure the planner time is properly utilized.
Ensure the translation of the job plan - is clear and understandable terms.
Remember the goal of planning is to eliminate the cause of the job and to eliminate the job in the future. To repair quickly is not the basic goal. The reason for maintenance planning is to eliminate the cause while overcoming the effects efficiently.

OPERATING A GOOD CHARACTERISTICS OF A GOOD MAINTENANCE MANAGEMENT SYSTEM

One of the prime characteristics of a good good computerized maintenance management system is that it has on-line inquiring and provide screen reviewing for the areas of work orders, materials and equipment.The work order is the controlling document in any maintenance management control program.When viewing the work order on a screen in a computerized program, the following information should be readily available ,
---The equipment in which such job could be done.
---The description of the work to be done.
---The level of the job priority
---The responsible charging centre for the cost incurred.
---The date the work order was written and the last date of the job and completion.
---The work backlog current status.
---The time required by craft in which the work could be completed.
---The work backlog current status.
---The time required by craft in which the work could be completed.
---The cost of labour required and material that is charged against the work order.
These are the information that may be desired but the forgoing are necessary for good maintenance management.It should also be a program that would be able to select and bring up work order for observation.However the selection criteria shall include the following:
- Cost area
- Equipment number
- Dates written,issued, completed or last worked.
- Priority level.
- Backlog status
- Cause or action taken
- Trade for instance medical,electrical,mechanical,instrument, .
- Supervisor
- Planner.
The section shall also have the ability to view
- Vendors performance specification
- Maximum and minimum qualities.
- Costs
-Recorder quantities
- Usage information on a periodic basis
Equipment --- the third level of a good maintenance management programme concerns equipment.Screen viewing for the selection includes.
-  Equipment list
- A work order list for this piece of equipment..
 

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Thursday, August 18, 2016

COMPUTERIzED MAINTENANCE MANAGEMENT

Organizational for implementation  of a computerized maintenance management program is one of the job of project team. Its implementation system and definition of the items would have to be stated as follows: The performance of the maintenance function planning and scheduling.

A. The performance of the front - end load semi permanent information such as cost centre,   employed list ,parts list and equipment list, cause code ,action code, budget or other information that is not changed on a daily and weekly basis, The definition of sequence necessary for the loading of this data are also included.

B. The system of maintenance of the files on a daily and weekly basis involves several persons such         as: i) A planner to load work orders. ii) A time clerk to load employees time sheets , iii). A store room clerk to load material requisition or any other appropriate combination. It is advisable to have individual information flowchart for streamlining of the system information ..

C, The performance of the security that is going to be part of the system, The definition and the procedure that should  be established as to who could enter and or modify information in the system various segment and reports updates.

D. Th performance form of data entry should also be designed for data entry, they should be computer-able with the computer entry format and include work time sheets and materials acquisition, (Richard,2005).
 The orientation of the various people concerned with the new computerized maintenance  management program is most important step after the organization.  This may take place as part of the organizing.. The orientation will be necessary from the highest levels of the facilities organization.to the lowest and including production staff as well as maintenance staff. The detail of the maintenance appropriate for the various  groups would be the cause element different. It is also appropriate to have concise progress review session as the information takes place. The orientation and the training are similar but there is some different. The orientation is informing people of what is going to be done or what is being done while training is instructing people on how to do something.
The training of personnel are the critical aspect of implementation of a computerized maintenance management program. The training minimally should includes the following:
---How to write a work request.
---How to follow up the priority system.
---How all data could be entered and the necessary procedures  for correct data inputs.
---Appropriate maintenance personnel planners and supervisors  etc plans on how to retrieve information.
---Maintenance management and supervision and appropriate maintenance production management on how to read and interpret reports and other available information.
In summary ,computerization maintenance  management is a demanding task, the benefit are normally significant, but it will enhance the following :Better labor utilization., 5 to 23%
                                                                        Equipment utilization 1 to 5%
                                                                        Stores inventory reduction 10 to 20%, (Richard,2005).

COMPUTERIzED MAINTENANCE MANAGEMENT

Organizational for implementation  of a computerized maintenance management program is one of the job of project team. Its implementation system and definition of the items would have to be stated as follows:The performance of the maintenance function planning and scheduling.

A. The performance of the front - end load semi permanent information such as cost centre,employed list ,parts list and equipment list, cause code ,action code,budget or other information that is not changed on a daily and weekly basis,The definition of sequence necessary for the loading of this data are also included.

B.The system of maintenance of the files on a daily and weekly basis involves several persons such         as: i) A planner to load work orders. ii) A time clerk to load employees time sheets,iii). A store room clerk to load material requisition or any other appropriate combination.It is advisable to have individual information flowchart for streamlining of the system information ..

C,The performance of the security that is going to be part of the system, The definition and the procedure that should  be established as to who could enter and or modify information in the system various segment and reports updates.

D. Th performance form of data entry should also be designed for data entry,they should be computer-able with the computer entry format and include work time sheets and materials acquisition, (Richard,2005).
 The orientation of the various people concerned with the new computerized maintenance  management program is most important step after the organization.This may take place as part of the organizing.. The orientation will be necessary from the highest levels of the facilities organization.to the lowest and including production staff as well as maintenance staff.The detail of the maintenance appropriate for the various  groups would be the cause element different. It is also appropriate to have concise progress review session as the information takes place. The orientation and the training are similar but there is some different.The orientation is informing people of what is going to be done or what is being done while training is instructing people on how to do something.
The training of personnel are the critical aspect of implementation of a computerized maintenance management program.The training minimally should includes the following:
---How to write a work request.
---How to follow up the priority system.
---How all data could be entered and the necessary procedures  for correct data inputs.
---Appropriate maintenance personnel (planners,supervisors etc) on how to retrieve information.
---Maintenance management and supervision and appropriate maintenance production management on how to read and interpret reports and other available information.
In summary ,computerization maintenance  management is a demanding task,the benefit are normally significant,but it will enhance the following :Better labor utilization., 5 to 23%
                                                                        Equipment utilization 1 to 5%
                                                                        Stores inventory reduction 10 to 20%, (Richard,2005).

Sunday, August 14, 2016

MAINTENANCE REPORTING SYSTEM , CONTINUE -1

The maintenance department will  assigned the service number as it received the work order and will then multiply the two numbers to achieve a priority number in each work order.,The lowest priority is then the number 2 and the highest priority is 90, the work order with highest priority number should be schedule first. A portion of the maintenance hour available,starting from 10 to 30 percent should be assigned to priority work lower than 30. This priority considers potential failure costs and keeps low priority equipment and department operating. The control aspect of PS is two fold The average PS by craft, identifies how important the backlog is for each craft and for maintenance in total.The average PS number by production department and or in the case of multiple plants provides knowledge of  the average level of maintenance.The PS number and man hour weighted average involved for each craft and each production involvement is calculated.The constrains of the activity can also be determined through the man hour of activity nodes and network evaluation data .Therefore the lower the man hour of any activity the  easier to approach, but in most maintenance activity there is always a case sensitive and priority.,For instance, compare two jobs,one has a PS number of 90 and requires 3 man hours of work by an electrician or mechanic,Another has a PS number of 30. and requires 1 man hour of work by an electrician. The weighted average would be :
90 PS x 3 man hour = 270
30 PS x 1 man hour =   30
addition of the man hours is equal to 300 man hour divided by the total man hour,would results to ,75 average.The minimum use of a system will easily identify acceptable control limits for many things, for example:
1.Authorize overtime for a work order with a PS number of 42 and higher
2.Sub- contract or add man hour in a craft with an average number of PS number of 56 or higher for more than 4 weeks and a constant trend up.
3.Transfer assigned manpower from lower priority to higher priority departments until the average PS number in the department reaches 42 or lower.                                    ---------

Thursday, August 11, 2016

MAINTENANCE REPORTING SYSTEM AND CONTROL

The most important aspect of any maintenance control system is priority systems that gives recognition to every piece of equipment in the plant .It must considers the plant utility and their transaction lines and various aspects of safety and environmental work.It must be simple enough for all to understand,rigid enough not to be abused, and flexible to covert the changing condition. The  system below shows how to properly handle this basis Its most important is that, it is a priority system assigned by both production and maintenance .
Priority system for planning and scheduling of all maintenance work are as follows and are arranged in order of priority as shown below
Production  Assisted work description                                     Maintenance  Assisted work description

 10. Equipment which will shut down the entire plant             9. Breakdown safety hazards                                                                                                                    where  loss             
 if not operating .All safety work orders.                                       of life or limb is probable.           


8.   Equipment that will shut down an entire department          7. Preventive maintenance                                                                                                                                 production
 if not operating.                                                  

  1.                                                                                              assistance.maintenance perform 

                                                                                                      ed during production.


  • 6   Equipment that will  reduce the output of the                     5 Repair to major parts or units                                                                                                               that are

  department if not running. Equipment that will shutdown            not running.Shut down of a                                                                                                                                               department
   an entire department if not running ,when installed spares           or major system Normal are available for immediate operation.                                                            health and  safety work.

ment that is important to the operation of a                          
                                                                                                  3.Shop work or other routinework a department but will not shut down the department of
4.Auxiliary equip      non                                                        repairs due to spare parts or units                                                                                                                are
 cause a major loss if not operating.                                      available for immediate production                                                                                                        runs  




.





2.Convenient items,cost saving equipment ,
     building roads                                                                      1.Painting for appearance or                                                                                                                          protection.
                                                                                                     The use of skill crafts for cleanup      .                                                                                                       other than their work 

.
To set up the PS system,identify every piece of equipment in the plant with production assigned even numbers published this list to all concerned and ascertain they thoroughly understand the concept.The production number should then be identified,on every work order in the case of dual purpose equipment or debatable number consider the productivity of the product and production schedules in assigning the production numbers. The production number can be change several times in a year to handle seasonal work and drastic changes in schedules.(Beachleg,1995.).

Thursday, August 4, 2016

THE MAINTENANCE REPORTING SYSTEM AND CONTROL

The maintenance steps being presented is a complete set of reports for control of a large and complex organisation, Those that involved in smaller and simpler operation may thus select the appropriate report that suits their organisation or specific situation.In most larger organisation which commonly used computer automation to record ,store ,calculate , and print reports.Smaller organisation generally must accomplished all these manually.The specific recommendation for smaller organisation are herein stated for their necessity, importance and values ,control reports must be sufficient ,correct information and decision must be made at the most appropriate period .The old methods of operating a maintenance department by recording only cost and evaluation is fast disappearing. Therefore the maintenance control should include the proper automation system,  for correlation of the following:preventive ,corrective.predictive maintenance techniques,routine,spares,work on down time and failure mode.work during production,minor alteration and construction,,safety of the environment and others.
Maintenance must be control on short ranges and annual basis to balance a major project activity and provide for orderly vacation and long range basis (over 1 to 10 years or more) to assure proper skill, space and equipment as needed (Enest,1995). The maintenance function is not a separate entity, though not even pure overhead but it is just as important as any other function .Though the relationship to stores, accounting ,engineering and other functions will be properly identified by reports  Below are summary of some of the  reports that will be detailed as the discussion continues :- Average PS number_indicates how important is the known work,by technical and production department .
.Backlog of activity :Indicates how work  would be required or could be stated as total work required.
-available to work.
-amount of work to be done or total work.
-labour sufficiency
-schedule compliance
-materials cost.
-present down time
-total department involved...
. .

STRATEGY MANAGEMENT IMPLEMENTATION ,

For strategy implementation,manager begin by planning how they will put the strategy into action.They determined the resources and the activities necessary to implement the strategy, then they use the organization  resources to carry out the plans.They manages who do not have much say in the organizations overall strategy and could apply thinking to the way their group helps implement that strategy.Given the key role that human resources play in sustaining a competitive advantage ,strategy implementation depends on the on effectively managing the human resources and applying the principle of organizational behavior which indicates that  managers must lead their employees they must link individual skills,personalities and the like to work requirements..They must create a climate an organizational that foster motivation, communication and opportunities to contributes to group and individual goals.And  manager must structure the organisation in such a way that it supports these activities.Today,s environment increasingly favors engineering organisation where a managers implement strategy by setting up an environment in which an employee could perform well,and getting out of professional orientation.In other words the manager gives the employee vision, the resources, the need to do their jobs and authority to make decisions.
STRATEGY CONTROL:Once the implementation of management of maintenance is under way managers would review the outcome of their efforts They need to see whether carrying out their plans might actually leads to implement its strategy. In addition,if the results are not actually what had been desired. They must considered whether organization needs to modify its strategy, in this way the organization performance influences future strategy formulation and planning.This feedback from control highlights an important aspect of strategy management of modern organization. It takes place in an environment of rapid and pervasive change. In such environment managers cannot afford to think of formulating a strategy as taking out of position.
This view result in a rapid strategy that slow down the organization when changes in the environment makes the strategy make absolute. Managers need to used feedback from strategy control along with information about the environment to device and revise strategies that encourage flexibility. The organization that are flexible in this sense will choose from among the tactics and control measures described herein .
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Monday, August 1, 2016

THE FUTURE OF PROGRAMMABLE CONTROLLER.

The future of the programmable controllers relies not only on the continuation of the new product developments but also on the integration of the PLCs with other control and factory management equipment PLCs are incorporated through network into computer integration Manufacturing (CIM) system,Combining their power and resources with numerical controls, robots,CAD and CAM systems,personal computer based systems and hierarchical computer based system. There is no doubt that programmable controller will play a substantial role in the factory of the future.
Programmable controllers new advance technology includes features such as better operate interfaces,graphic user interface (GUIs) and more human oriented man and machine interfaces (such as voice modules) they also includes the development of interfaces that allow communication with the equipment, hardware, software that supports artificial intelligence,such as fuzzy logic i and o systems.
Software advances provide better connection between different equipment,using communication standards through widely used networks. New PLC instructions are developed out of the need to add intelligence to a controller, knowledge based on process learning type instruction may be introduced to enhance the capabilities of a system.The user;s concept of the Flexible Manufacturing System (FMS) would determine the control philosophy of the future.The future would almost certainly continue to cost programmable controllers as an important player in the oil industry and factory.
Control strategies will be distributed with intelligence instead of being centralized.Super PLC would be used in plant automation and other applications requiring complex,calculation, network communication,supervision of smaller PLCs and machines controllers..