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on Maintenance Reliability

A listing in reverse chronological order of these article series:



  • Usman Mustafa Syed — Aasan Asset Management series

  • Arun Gowtham — AI & Predictive Maintenance series

  • Miguel Pengel — Asset Management in the Mining Industry series

  • Bryan Christiansen — CMMS and Reliability series

  • James Reyes-Picknell — Conscious Asset series

  • Alex Williams — EAM & CMMS series

  • Nancy Regan — Everday RCM series

  • Karl Burnett — History of Maintenance Management series

  • Mike Sondalini — Life Cycle Asset Management series

  • James Kovacevic — Maintenance and Reliability series

  • Mike Sondalini — Maintenance Management series

  • Mike Sondalini — Plant Maintenance series

  • Andrew Kelleher — Process Plant Reliability Engineering series

  • George Williams and Joe Anderson — The ReliabilityXperience series

  • Doug Plucknette — RCM Blitz series

  • Robert Kalwarowsky — Rob's Reliability Project series

  • Gina Tabasso — The Intelligent Transformer Blog series

  • Tor Idhammar — The People Side of Maintenance series

  • André-Michel Ferrari — The Reliability Mindset series

by Doug Plucknette Leave a Comment

10 Proactive Activities & Measures to Improve Your HSE Program

10 Proactive Activities & Measures to Improve Your HSE Program

In past articles I have often referenced Dr. Aubrey Daniels and the use of Behavioral Psychology and Analysis in the workplace. In the late 1980’s I was fortunate enough to attend a 2-week course in Performance Management put on by Dr. Daniels and two of his associates where we learned the importance of measuring behaviors as opposed to results. To say that this course was enlightening would be an understatement as it was in this class I first learned why we need to measure leading indicators as opposed to results. [Read more…]

Filed Under: Articles, on Maintenance Reliability, RCM Blitz

by Mike Sondalini Leave a Comment

The 9 Great Benefits of a CMMS*

The 9 Great Benefits of a CMMS*

A computerised maintenance management system (CMMS) is the maintenance department’s most important tool. It provides insight into the behaviour of the facility’s individual assets, i.e. the plant and equipment. For a CMMS to be of use it must be used as an information ‘bank’ that can be investigated. There are 9 really good reasons to use a CMMS. And each one of them alone makes a CMMS worth having. [Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

by Mike Sondalini 1 Comment

Lubrication Cleanliness & Filtration

Lubrication Cleanliness & Filtration

When oil in gearboxes become contaminated there is a rapid loss of bearing operating life. It is critical that metal particles, dirt, sand, oxidisation products, etc be removed from the oil before they gouge and tear-up the finely toleranced machine parts. Oil replacement, contamination prevention and oil filtration are common practices religiously adopted by the best in the equipment reliability management business. This article explains the fine requirements for successful contamination control to insure long trouble- free equipment life. [Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

by Doug Plucknette 1 Comment

10 Sure Signs That Safety Isn’t First

10 Sure Signs That Safety Isn’t First

In nearly 40 years I’ve seen it all, from those who are proud to be the best to plant sites that are in such a deplorable state, you hope you get through the tour without some type of injury, fire or explosion.

The first thing I learned when I began providing Asset Management and Reliability Centered Maintenance services as a consultant was how lucky I was to have worked my first 19 years for a company who took Employee Health, Safety and Environment seriously. In that time, I don’t remember ever wondering if the people I worked with or the Managers I worked for considered Health, Safety and Environment as the top priority. It was stated almost every day and reinforced with every job we performed through lock-out, tag-out procedures.

[Read more…]

Filed Under: Articles, on Maintenance Reliability, RCM Blitz

by Mike Sondalini 1 Comment

Fired Packaged Boiler Basics

Fired Packaged Boiler Basics

Steam boilers not used for power generation and of smaller size and energy output are termed packaged boilers. The heat source is usually either electric coils or a burning fuel. When a flame is used to heat the water it is known as a fired packaged boiler. Fired boilers are considered efficient steam generators with about 85% of the available energy converted to steam. They can be of water-tube or fire-tube design. Boilers incorporate many key aspects of heat transfer to create steam from water. This article describes how fired boilers work and their key components. [Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

by Mike Sondalini Leave a Comment

Heat Transfer Basics

Heat Transfer Basics

Heat is energy and its nature is to flow from a state of high excitement to one of low excitement. Heat is transferred from a hot place to a cold place by convection, conduction or radiation. This article explains the three modes of heat transfer and provides simple examples of each. Methods to reduce and increase heat transfer are also presented. [Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

by Doug Plucknette Leave a Comment

5 Common Questions on the IIoT (Industrial Internet of Things)

5 Common Questions on the IIoT (Industrial Internet of Things)

In continuing this year’s theme regarding common questions on relevant topics, today I have the 5 most common questions people have been asking me about the Industrial Internet of Things. Like every other article or Blog I have posted in the past I encourage you to all to jump into the conversation by asking questions or providing comments to my questions and answers. [Read more…]

Filed Under: Articles, on Maintenance Reliability, RCM Blitz

by Mike Sondalini 1 Comment

Conductivity Meter Operation & Use

Conductivity Meter Operation & Use

The electrical conductivity (and its opposite, resistivity) of water based solutions indicate its electrical current carrying ability. High conductivity occurs when many charged atoms and ions are in the water. This typically means the presence of dissolved metals, salts, acidic or alkali chemicals. Conductivity probes are used to measure the total level of charged particles present. This article explains how conductivity probes work and their application in boiler water treatment and management. [Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

by Doug Plucknette 1 Comment

Reliability Centered Maintenance – Common Questions

Reliability Centered Maintenance – Common Questions

When is the best time to do an RCM analysis on your equipment?

While RCM Blitz™ can be applied at any time in the asset lifecycle, the best time to do an RCM analysis is in the design phase of a capital project. Reliability Centered Design is much more than a thorough RCM analysis on a critical asset, it also uses [Read more…]

Filed Under: Articles, on Maintenance Reliability, RCM Blitz

by Mike Sondalini 1 Comment

Pump Life Extension — The Impeller

Pump Life Extension — The Impeller

A spinning pump impeller provides the means to draw incoming product through the pump, energise it, and then force it out under pressure. The impeller coverts the electrical energy from the motor into hydraulic energy of the liquid. It does this by taking the liquid into the center of the impeller and flinging it outward at high speed. To efficiently continue to do this the impeller must remain in the same condition as it was when first installed. If the impeller deteriorates the conversion from electrical to hydraulic energy becomes inefficient. Power is wasted, flow and pressure fall and the pump cannot do its designed duty. [Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

by Mike Sondalini Leave a Comment

Equipment Criticality

Equipment Criticality

How do you decide what level and type of maintenance to use on an individual item of plant and its sub-assemblies? Not all equipment is equally important to your business. Some are critical to production and without them the process stops. Others are important and will eventually affect production if they cannot be returned to service in time. While other items of plant are not important at all and can fail and not affect production for a very long time. [Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

by Doug Plucknette Leave a Comment

How To Create An Environment of Innovation

How To Create An Environment of Innovation

I found myself seated next to a corporate executive in a recent flight out of Atlanta, while I was attempting to read a book, he was yammering away on his cell phone about quarterly results and the need for a reduction in head count.  Hearing this, my hopes of becoming engrossed in a good book was now over. Now I’m just upset at how some folks seem to make life changing decisions with such little regard or emotion. [Read more…]

Filed Under: Articles, on Maintenance Reliability, RCM Blitz

by Mike Sondalini 1 Comment

Belt Conveyor Tuning

Belt Conveyor Tuning

A belt conveyor is a moving surface used to transport product from one end to the other. In its basic form it consists of a driving head pulley, a tail pulley, the moving belt, support rollers, cleaning devices, tensioning mechanisms and a structural frame. Though simple in concept its many components need to work together as a system to get the best performance and operating life. Critical to that is an understanding of how to care for a belt conveyor and tune it for successful operation. [Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

by Doug Plucknette Leave a Comment

Reliability Centered Everything?

Reliability Centered Everything?

I get mad at Stan Nowlan and Howard Heap from time to time. Twenty years ago their work titled Reliability Centered Maintenance became the focus of my life when I first discovered the impact that RCM could have on manufacturing reliability. Since that time, I have authored somewhere around fifty articles on the subject, been a featured speaker at nearly three conferences a year and several years ago I even completed a book on the subject, describing what I see as the most effective way to complete a RCM analysis as well as the impact it can have on equipment and process reliability (Reliability Centered Maintenance using RCM Blitz™). For those who have taken the time to become educated in what a good RCM analysis is all about, they know power of this tool and where it applies. I know from experience, Reliability Centered Maintenance can and will deliver incredible results. [Read more…]

Filed Under: Articles, on Maintenance Reliability, RCM Blitz

by Mike Sondalini Leave a Comment

Moving Slurries About

Moving Slurries About

Moving slurries about. Slurry is solid particles in a liquid. Concentration can vary from mostly liquid to mostly solid. Slurries are usually transported through pipe work using pumps, pressurised gas or steam. Different concentrations and different particulate produce different flow characteristics. Successful slurry transport requires knowledge of the particulate, its transport behaviour in the liquid at different concentrations and speeds, the nature and friction effects of the pipe work system and selection of the right motive method for the application. This article provides information for transporting slurries of up to 60% solids concentration. [Read more…]

Filed Under: Articles, on Maintenance Reliability, Plant Maintenance

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