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Most mornings after he completes his 5-mile run, Rob Robertson, vice president-coal preparation, United Coal, a subsidiary of the Ukrainian steel producer Metinvest, grabs a cup of coffee and spends [...]

Ten times more? That number represents a flexible coupling's capability for misalignment compared to the tolerance of rotating equipment. That means system alignment should be based first on the minimum [...]

Over the past two decades PLANT ENGINEERING magazine has been publishing the entrants and winners in our Tips & Tricks competition. Since 1994 we have limited the winners to three, [...]

Key Concepts * Properly functioning steam traps conserve energy and save money. * Each steam trap has unique operating and failure characteristics. * Electronic monitoring can oversee hundreds of traps [...]

Time conserving, money-saving, aggravation-avoiding ideas for solving typical maintenance problems should be shared with others in the plant engineering profession. This idea-exchange concept serves as the basic philosophy for PLANT [...]

Because of features such as improved ease of use, web-enabled functionality, the ability to integrate applications across the enterprise, and much more, software is providing plant engineers with excellent assistance [...]

When optimizing the efficiency of heat-recovery steam generators (HRSGs,) fully understanding the temperature profiles of these units is crucial. Gas turbine HRSGS are unique and pose peculiar problems as compared [...]

Develop checklists to identify control areas for operations and maintenance departments Controlling plant emissions mitigates environmental problems, but also improves the facility's economic/profitability condition. To get a better view of [...]

Achieve on-time, within-budget engineering and construction jobs Successful projects will result by following logical and proven project execution practices. Executing according to the practices presented here can result in a [...]

One of the fundamentals of good operations management practices is the "complete kit" concept, which suggests that work should not start until all the items required for completion of a job are available. These items (the kit) include components, tools, drawings and information. Starting a job with an incomplete kit means more labor time to finish the job, longer lead time, more work in process, reduction of throughput, poor quality and impairment of due date performance. This paper analyses the various facets of the complete kit approach by an analytical model that shows when it is preferable to use this concept. The tendency of practitioners to work with incomplete kits is explained using the prisoner's dilemma.

We consider a single unit working in a continuous mode of operation characterized by an increasing failure rate. We determine the optimal number of preventive maintenance activities to be scheduled within a time horizon of interest, the required extent of the preventive maintenance by means of an age reduction of the unit and the corresponding optimal value of the expected profit. We assume that any breakdown occuring is minimally repaired, the repair is performed instantaneously, and the repair cost is the same for any repair. On the other hand, the cost associated with a preventive maintenance activity may vary as well as its duration.

Gas detectors are indispensable to the safety and industrial hygiene programs of any manufacturing plant that utilizes gaseous or liquid chemicals. These equipment support portable detection instrumentation that protects personnel and equipment from gas leaks and unplanned emissions. Persons in charge of monitoring gas detectors should utilize an inventory of onsite chemicals that may pose hazards. They should also establish a safety program that educates personnel about gas delivery areas and process equipment., Any manufacturing plant that uses gaseous or liquid chemicals may experience leaks or other fugitive (unplanned) emissions. Gases and liquid vapors may quickly disperse, posing an immediate threat to employees [...]

Your foundry needs to replace old run-down equipment or maybe increase capacity, but the check-book is tight and time is short. The equipment is needed immediately, if not yesterday, and [...]

Achieving efficiency in dock operations requires an analysis of major concerns which include trends, safety and equipment. Trailer configurations have a direct effect on the operation and efficiency of the dock equipment. Trailers equipped with air ride suspensions offer advantages such as improved driver comfort and load cushioning. Safe dock operation is one of the main thrusts of plant management for increased productivity and reduced cost in insurance premiums., A detailed look at the trends, safety considerations, and equipment that combine to create an efficient operation The loading dock has come a long way since its back-of-the-plant, unsightly, unsafe, [...]

Successful baghouse collection system design can be achieved by first analyzing the dust to be captured and determining specific application requirements. The application requirements concern determining the most appropriate filtration media and determining the air-to-cloth ratio. Among the important dust factors that should be evaluated are dust type and nature of generation, capture or conveying method, particle characteristics, maintenance, concentration, air temperature and air volume., Determining dust characteristics, choosing filtration media, and picking the air-to-cloth ratio are key steps A thorough analysis of the dust to be captured and determination of specific application requirements are [...]

An area of plant engineering where cost reductions can be obtained is in low-voltage fuse applications. This reduction can be realized through the proper selection of fuses, coordination in the handling of blown fuses, quick identification and replacement of blown fuses and by minimizing the required fuse inventories. There are several available techniques and equipment for the accomplishment of these cost-saving measures. Downtime as a result of blown fuses are significantly minimized by implementing these measures., Fuse-related costs can be cut substantially by using the latest advances Fuse-related expenses are typically not high on the list of plant engineering cost-cutting opportunities. But the total costs incurred [...]

Libyan Cement Company Inc. (LCC), under its Austrian management, Asamer Group, has competed its environmental projects and modernization of the new line Benghazi III. LCC's three plants were all equipped with state of the art environmental protection systems to reduce dust emissions by more than 95%. How the projects were implemented is also discussed.

A look at the options offered by natural gas techniques helps find the best low [No.sub.x] solution Solving the [NO.sub.x] dilemma and finding the best technique or technology to reduce [...]

Fall is here, which means now is a good time to climb up on the roof and inspect it in preparation for the winter months ahead. With today's roofing systems [...]

A door is defined as 'any movable structure used to close off the entrance to a room, building, or covered enclosure.' Movable is a key word in this definition because [...]

Ideas for simple, better solutions to commonplace plant engineering problems deserve to be shared with your compatriots in the profession. In our 04/26/ 90 issue, the editors of PLANT ENGINEERING [...]

Selecting an HVAC System One decision that must be made early in the planning stages of any renovation or new building construction project is how to heat and cool the [...]

Rotating equipment shop testing POOR PERFORMANCE of machinery after commissioning at first draws comments on whether the purchase specification was in order, whether there were any lapses in stage inspection [...]

Now here, you see, it takes all the running you can do, to keep in the same place. If you want to get somewhere else, you must run at least [...]

Good problem solvers are among the most highly sought after individuals in existence today. In most cases companies and organization have already identified their skilled problem and consider these individuals [...]

EDITOR'S NOTE: The past decade has seen the development of a number of manufacturing management concepts. Chief among them are: lean manufacturing, Six Sigma, supply chain management, total productive maintenance [...]

Several factors should be considered when troubleshooting lubrication problems associated with grease use and antiseize selection. Maintenance staff should consider the viscosity requirements in grease selections and examine the speed factors of bearings. Moreover, maintenance personnel are advised to gauge the temperature requirements of synthetic-based lubricants before using them. They should also appraise the compatibility of seal materials with mineral-oil based lubricants to prevent recurring problems., When a lubricated component such as a bearing fails, the top priority is often to remove, replace, and restart. Unfortunately, that leaves little opportunity to evaluate the problem and understand [...]

Bearing service life is dependent on factors such as proper handling, storage, installation, and maintenance. Most failures in bearing operations are attributed to improper lubrication or installation. The maintenance department can achieve a realistic goal of reducing its failure rate by adopting proper maintenance procedures. Abusive handling can cause extensive damage to bearings, while storage is also an important consideration for equipment handling, especially for bearings which have not been used for quite sometime., About 90% of all rolling element bearings fail prematurely due to factors related to general maintenance practices Long-term bearing operation cannot be achieved unless proper handling, storage, installation, and maintenance [...]

Rolling steel doors are a common sight in plant facilities. Plant operators should be trained on the basic use and operation of steel doors to minimize problems and maximize the use of such equipment. Door maintenance and repair can be more tedious than what is normally expected. Thus, companies should also consider establishing a service relationship with an outside door specialty company., Establishing operational procedures and developing a regular maintenance schedule reduce costs and increase service life Rolling steel service, counter, and fire doors are common in industrial settings. Their comparatively low [...]

Technological advances have brought about new vehicles, such as very narrow aisle and automatic guided vehicles. However, some facilities have found out that their floors do not have the appropriate flatness required for the operation of such high-tech equipment. In such situations, one should first determine the flatness required. The existing floor should then be surveyed to determine the repairs needed. This would allow engineers to determine whether the floor should be repaired or totally replaced., What do you do when your plant floor needs to be flat, but isn't? With the upgrading of facilities, ordinary concrete floors that used to support machine tools and low-rise [...]

By Gary Wamsley, JoGar Energy Services A large pulp mill was shut down due to failure of the forced draft fan on its recovery boiler. Excessive vibration of the inboard [...]

Mezzanines inherently create more room for storing parts, tools, and maintenance inventory by taking advantage of all available vertical space. The double-layered system is the answer to storage problems where [...]

Flexible Piping Systems: Ready For The Future Flexible piping systems should be responsive and adaptable to future changes. These typically take the form of load additions or the shifting of [...]

Survey-Based Lubrication Program Adds to Bottom Line A well-designed and implemented, scientifically based lubrication program leads to awareness of inadequate machine element designs and other maintenance deficiencies not directly related [...]

By Hal Ettinger Plant layout is the engine that powers the printing plant-- and you control the horsepower. But a poorly designed layout can be your worst enemy, eroding your [...]

By Ron Moore, The RM Group, Inc. Most all companies are determined to improve their performance and become ever more competitive. Most try various tools for improving their performance, but [...]

By Mike Laszkiewicz, Rockwell Automation With maintenance-related activities accounting for a substantial portion of the total operating costs for manufacturing plants, manufacturers are placing increased emphasis on effectively managing production [...]

By Pierre Husson, Husson, Inc. Dirt, dust and debris cling to plastic sheets. Previously-inspected electronic components don't work. Wood parts twist and warp. Paper and cardboard shrink and warp, jamming [...]

By Daniel J. Szoch, The Timken Company Rotating equipment can deliver optimal performance and long life reliability if installed, maintained and operated properly. Increasingly, condition monitoring devices - part of [...]

Better think outside the grid by dusting off Y2K contingency plans and investing in backup systems that will cover you in case someone pulls the plug on your power supply,' [...]

Managers generally seek to centralize efforts in order to better use resources and maintain control. When faced with similar tasks scattered across multiple entities the natural tendency is to try [...]

EDITOR'S NOTE: The past decade has seen the development of a number of manufacturing management concepts. Chief among them are: lean manufacturing, six sigma, supply chain management, total productive maintenance [...]

Problem: Cleaning paper-board core paint rollers is a time-consuming job. Is there a faster, easier way? Solution: Shove a short extension handle into the ground and screw a paint roller [...]

Fire, smoke, and combination fire/smoke damper products are offered in compliance with new UL 555 and UL 555S testing requirements, more than a year ahead of the July 2002 deadline. [...]

Over the past year, I've developed a new, deeper respect for what plant engineers go through on a regular basis. I've been going through a major remodeling project on my [...]