Do you have a document you use for equipment overhaul/rebuild/repair? I'm trying to create one that can be placed in maint history for reference. Also something I can hand to station management and stamp the machine ready for service.

I would like to apply real numbers as much as possible while allowing subjective reasoning. Any industrial standards out there?

Subjective reasoning? A bearing at 140F is too hot to touch but it's not too hot to run. We would like all bearings cool enough so you can place you hand on and most of them you can. But 140F isn't a big deal. From my understanding oil is rated at 12K - 16K operating hours at 160F with 1/2 decrease in life expectancy every 15F - 18F above that. So if it's 140F outside it might be 180F inside, you'd better change the oil every year. But I would not recommended removing the machine from service for maintenance again.

Show me what you got and I'll show you what I end up with.

Points I'm considering - captured after running 24 hours.

1. Bearing temperature
2. Bearing vibration
3. Motor amps (rating on the name plate)
4. Motor temperature
5. Pump performance

quote:

Do you have a document you use for equipment overhaul/rebuild/repair?

Just the overhaul/rebuild/repair order.

We have that also (SAP). But the info from the maint repair is not enough.

I want to capture some more data and input it into the maint history and use it to call the return to service - satisfactory 8-)

Activate measuring points for the equipment to record the data at the maintenance orders?

Just a "return to service" document that has several parameters that shows machine health and gives us the ability to tell maintenance dept that it's running good.

It would be reasonable and valuable to place it into the work order history.

Are you reffering to a paper document/form to file at the Equipment Manintenance History file, or an electronic document like a maintenance order at the CMMS?

Let Operations sign-off the workorder,
We call that the performance test.
Give them also a place to sign "under protest" and some room to write up their complaints.

Not assigned workorders are not closed (sent to history) in our plants.

quote:

Points I'm considering - captured after running 24 hours.

1. Bearing temperature
2. Bearing vibration
3. Motor amps (rating on the name plate)
4. Motor temperature
5. Pump performance

Pump performance is subjective, if you ask 10 people you get 50 different answers.

Bearing temperature ,do they know the normal temperature? With they I mean the people who "know" the equipment (maintainers / operators), the people who are seeing/hearing/smelling the equipment everyday, not the occupants of Mt Olympus

Remember, every equipment has its specific operating condition, thus it would be dangerous to create a "one size fits all" shoe.

Pump performance always increases if they open the valves. In 70% of the cases there is a valve problem after startup

• suction/discharge valve
  
• steam jacket valves
  
• cooling water valves
  
• steam quench valves etc..
  

.. because someone forgot to open them again..

Are you talking about post-maintenance checks? There is a US military standard for this including pre-maintenance checks.

Normally following the overhaul, repair or rebuild done by a contractor or inhouse, there should be a report written for maintenance history or future reference purposes.

Anyway, site acceptance test by operations appears to be a must to signal a handover from maintenance with possibly a punchlist items listed clearly (if any) for subsequent rectification.

At the end of shutdowns, it appears to be a good practice to have forms for signature by relevant parties to signify proper handovers (as a part and parcel of a good shutdown or turnaround management).

This message has been edited. Last edited by: Josh,

Ideal situation would call for operations to give it a good going over. As they do. But RTS acceptance is subjective.

I think a better way to decribe it would be a "as new" bench mark data collection that can double as a RTS acceptance doc.

Here is what I have so far - from a real BFP event with a real broken shaft - in March 06.

RTS_sample.pdf (29 Kb, 18 downloads)

What means the last X at the Acceptable column? Is it like a overall evaluation on equipment conditions summarizing all above checks?
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I would add a box area where Maintenance would comment/discuss briefly their evaluation of equipment condition after the job.

To some managers six (6) X at the Not Acceptable column vs a lot more at the Acceptable column could mean the equipment is not that bad and can return to service without detecting that one or two of the Not Acceptable X's require that certain action or descision must be taken before turning this piece ON.

That RTS was easier than most. The unit was curtailed @100mws until it could be released. Most initail RTS problems involve some of the smaller details.

I was able to capture some of the limitations from operational inspection guidelines and defined vibration amplitudes based on RPM's using a 1970's document. It makes my job a little easier. Mils is responsive at 1X more than vane, blade or ball pass.

Bearing temperatures are a little tough. lubication fails much lower than the metal melts. If it's hot outside then it's really hot inside. Without thermal couplings it falls on sampling and changing more often.

Pump performance is neat. Without design curves - or - if it never has operated at design, I compare apples to apples. I try to use 4 equeal machines and the best one becomes the bench mark. Also if the pump is doing what we want it to (amps might be higher than before but still below red line) - why fix it.

To call the pump acceptable (even with the (6) X's) I called for a consensus. Helps going forward and commits maint to adjust/watch the packing leaks. Also OPS watches oil temps as the machine does it's work.

I see a pump and a motor with a hydraulic coupling between the two (maybe a torque converter).

The motor turns at 3600 rpm and the pump turns magically at 1280 rpm and it spits a load at 1900 psi

They have canibalized the suction and discharge pressure indications, after the first reading, thus we know nothing about the pump performance.
Maybe they have closed the tank lined up to this pump and some reliief valve opened, or you are currently making a big spill.
I don't think it is water that is being pumped, but according to all the bells and wistless on this thing, it must be expensive.

By the way, what is an RTS

RTS : Return to Service

Service report after the repair/rebuild is done.

If I'm on the Maintenance Department of a plant I will document the "RTS" at the same Maintenance Order. Where I see the RTS as another document is if I were a contractor and I wrote a "service report" for my clients when I complete the repairs or rebuild on the equipment they sent to my shop.